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UGH030-0212b_HTC Rev 1A.qxd

1. iaia aii T right side as view from the control panel Description 2 5 How it Works EarthSmart ECA Series Air cooled Models Process circulation 1 Hot fluid from the process enters the chiller SSS Es through the From Process connection into the pump reservoir e The pump moves fluid from pump reservoir through evaporator where it is chilled The process fluid is chilled in the evaporator and exits through the Process connec tion returning to the process left side as view from the control panel 2 6 Description How it Works EarthSmart ECA Series Air cooled Models continued Refrigerant circulation The evaporator extracts heat from the process fluid causing the refrigerant to vaporize evaporate into a gas Vaporized refrigerant travels to the compressor where the low pressure vapor is compressed into a high pressure high temperature vapor The high pressure high temperature vapor travels from the compressor through the condenser where the fan cools and condenses the vapor into a high pressure high temperature liquid High pressu
2. left side as view from the control panel 1 Hot gas bypass valve HGBP e Fan s amp Condenser 6 Compressor Process pump Pump reservoir Evaporator Filter dryer TX valve Expansion valve right side as view from the control panel Flow switch a Liquid line solenoid valve LLSV D Y strainer temperature sensor 14 From temperature sensor Evaporator temperature sensor Liquid line sight glass Description 2 9 Specifications EarthSmart ECW Series Water cooled Models Performance characteristics Nominal capacity tons kW 16456 2 9 102 54 19 0 73 257 10 3 362 15 2 53 5 19 4 682 24 4 858 319 112 2 Compressor qty Hp kW 1 1 5 1 12 1 3 2 24 1 5 3 73 1 7 5 5 59 1 10 7 46 1 15 11 19 1 20 14 91 1 25 18 64 1 30 22 37 Standard process pump Hp kW 0 75 0 56 10 075 15013 15112 15112 20 150 300225 30 225 50 373 Standard process flow gpm l min 4 0 15 1 7 0 26 5 14 0 53 0 18 0 68 1 26 0 98 4 37 0 140 0 48 0 181 7 60 0 227 1 79 0 299 0 Standard process pressure PSI bar 33 0 2 28 38 0 2 62 42 0 2 9 41 0 2 83 39 0 2 69 37 0 2 55 33 0 2 28 27 0 1 86
3. C 1 Appendix Water quality D 1 Appendix Overhead plumbing details E 1 Appendix RTD resistance F 1 Appendix Installing autofill optional G 1 Appendix Cleaning the autofill valve optional H 1 Table of Contents v vi Table of Contents Appendix Compressor module troubleshooting 1 1 Appendix Motor protection eee aes 1 Appendix EarthSmart chiller Serial Modbus communications K 1 EarthSmart chiller Ethernet communications K 2 EarthSmart chiller Modbus and Ethernet communications K 4 Appendix Pressure switch settings cece ee eee L 1 Appendix Resetting the high pressure M 1 SECTION on c 9 9 Introduction Purpose of the user 1 2 How the guide is organized 1 2 Your responsibilities as a user 1 3 ATTENTION Read this so no one gets hurt 1 4 How to use the lockout device optional 1 6 Introduction 1 1 1 2 Introduction ue Purpose of the User Guide This User Guide describes Conair s EarthSmart Portable Chiller and explains step by step how to install operate maintain and repair this equipm
4. ES ndn outside of chiller cabinet __ 5 p p e j 1 i 1 2 inch Fluid circuit i Acid plugs solution 1 lt lt To Process Pump connection continued Cleaning the Brazed Plate Evaporator or Water cooled Condenser continued A CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting 11 Re install the RTD for the evaporator or condenser NOTE These connections 12 For the evaporator open the To Process and From Process valves may vary depending on the factory optional model you have purchased Be sure to see the labeling 12b For the condenser open the condenser inlet and outlet valves on your particular unit 13 Replace the chiller s side panels 14 Reapply main power Maintenance 5 9 Replacement air filters are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 amp NOTE Conair recommends cleaning the air cooled chiller s exhaust fan blades when cleaning the filter 5 10 Maintenance Cleaning the Air Cooled Condenser AX WARNING Electrical Hazard Before performing any work on this item disconnect and lock out
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7. 3 3 Preparing for 3 4 Making process plumbing connections 3 5 Filling the chiller gt cece cece III 3 7 Checking refrigerant charge 3 9 Connecting the main power source 3 10 Checking electrical connections 3 12 Checking pump rotation 3 13 Checking the scroll compressor 3 14 Checking the water level gauge 3 14 Adjusting the bypass valve 3 15 Installing alarm indicators optional 3 16 4 1 Operation ii Table of Contents Basic control 4 4 EarthSmart Chiller control functions 4 5 Control function flow charts 4 5 How to navigate the 4 5 EarthSmart Chiller menu 4 6 Control function 5 4 14 Before Starting i Saye Sakae ees aha Sei 4 40 starting the ETE UU ERE UE Res 4 41 Stopping the chiller 1 encreire rae eens 4 42 EarthSmart Chiller sequence of 4 43 Adjusting setpoint temperature
8. 1 2 Your responsibilities as a 1 3 ATTENTION Read this so no one gets hurt 1 4 How to use the lockout device 1 6 2 1 Description What is the EarthSmart Portable 2 2 Typical applications 2 3 Rr Race xac s 2 3 How it works EarthSmart ECW Series Water cooled models 2 4 Process Circulation xau Fur urere rr RI ere Rer 2 4 Refrigerant 2 5 How it works EarthSmart ECA Series Air cooled models 2 6 Process circulation 1 een n e 2 6 Refrigerant circulation 2 7 Portable chiller features let p e 2 8 Water cooled models eret 2 8 Air cooled 2 9 Specifications iii ua us RR RR RR ERREUR RR 2 10 EarthSmart ECW Series Water cooled models 2 10 EarthSmart ECA Series Air cooled models 2 11 PUMP CUIVES i uet e RR OR 2 12 ECW Series 2 12 ECA Series 0 2 13 EarthSmart chiller 2 14 Table of Contents i 3 1 Installation Unpacking the boxes 3 2 Warnings and cautions
9. Adjusting the low pressure inhibit time Adjusting the low pressure delay time Adjusting the flow switch alarm inhibit Adjusting the flow switch alarm delay time Adjusting the process high alarm setpoint Adjusting the process high alarm inhibit TING Pr Adjusting the process high alarm delay time Adjusting the process high temperature shutdown setpoint Adjusting the process high temperature shutdown inhibit time 2 enw n Adjusting the process high temperature shutdown delay time Adjusting the process low alarm setpoint Adjusting the process low alarm ME ec ie ek Be Be E Adjusting the process low alarm delay Poe RS Adjusting the process deviation high alarm setpoint Adjusting the process deviation low alarm lt 4 71 Adjusting the process deviation high alarm inhibit time 4 72 Adjusting the process deviation high alarm delay d Rew aed 4 73 Adjusting the process deviation low shutdown alarm setpoint 4 74 Enabling Disabling process loop break 4 75 Adjusting the process loop break timer 4 76 Adjusting the alarm silence timer 4 77 Adjusting the autofill alarm timer 4 78 Adjusting the compressor cycles per hour alarm 4 23 9 343 Ro ee ea 5 4 79
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12. 5 14 Cleaning the evaporator and condenser Y strainer 5 16 Checking or cleaning the flow switch 5 20 Checking reservoir level cee eee II 5 22 Checking pump performance 5 23 Reloading factory default parameters 5 24 6 1 Troubleshooting iv Table of Contents Before beginning sa 6 2 Identify the cause of a problem 6 2 A Tew words of Caution ore 6 3 TROUBLESHOOTING Chiller 6 4 Autotuning errors ce e RR RR 6 6 Passe alarms tisiko 6 8 Shut dowr alarms 6 13 Additional alarms 6 20 Replacing 6 22 Removing pump components 6 23 Replacing the contactor aie emn 6 24 Appendix We re A 1 How to contact customer service A 1 Before you omms A 1 Equipment guarantee A 2 Performance A 2 Warranty limitations A 2 Appendix Maintenance 100 1 Appendix Pressure
13. oFF Function This screen displays the Compressor Cycle Q Count Reset This setting is used to clear NOTE Grey shaded the cycle count on screen 76 when replac screens denote supervi ing the motor starter of the compressor sor functions To access Use the and buttons to reset the the supervisor screens compressor cycle count see Operation section entitled Using the Supervisor s Password This screen displays the Hot gas Bypass Valve Cycle Count Reset This setting is used to clear the cycle count on screen 78 when replacing the Hot gas Bypass valve Use the and buttons to reset the Hot gas Bypass valve cycle count This screen displays the Process Pump Cycle Count Reset This setting is used to clear the cycle count on screen 80 when replacing the process pump Use the and buttons to reset the process pump cycle count This screen displays the Fan Cycle Count Reset This setting is used to clear the cycle count on screen 82 when replacing the fan Use the and buttons to reset the fan cycle count Operation 4 35 4 36 Operation Control Function Descriptions continued Screen o Q tr 2 oFF Ld d 2 tr 2 o a oFF Function This screen displays the Liquid Line Solenoid Valve Cycle Count Reset This setting is used to clear the cycle count on screen 77 when replacing the Liquid Line Solenoid va
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16. Thorough review of the equipment itself with careful attention to voltage sources intended use and warning labels Thorough review of instruction manuals for associated equipment Step by step adherence to instructions outlined in this User Guide Introduction 1 3 1 4 Introduction ATTENTION Read this so no one gets hurt We design equipment with the user s safety in mind You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide A WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should be installed adjusted and serviced by a quali fied technician who is familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by a qualified electrical technician in accordance with electrical codes in your region Always maintain a safe ground Do not operate this equipment at power levels other than what is specified on the machine serial tag and data plate N WARNING Voltage hazard This equipment is powered by three phase alternating current as specified on the machine serial tag and data plate A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure Improper grounding can result i
17. 5 2 4 Process circulation 2 4 gN Refrigerant circulation 2 5 B How it works EarthSmart ECA Series Air cooled models 2 6 Process 2 6 Refrigerant circulation 2 7 Portable chiller 2 8 Water cooled models 2 8 Air cooled 5 2 9 Specifications s vet eos a wee 2 10 EarthSmart ECW Series Water cooled models 2 10 EarthSmart ECA Series Air cooled models 2 11 Pump 2 12 ECW Series Water cooled 2 12 ECA Series Air cooled 2 13 EarthSmart chiller options 2 14 Description 2 1 2 2 Description What is the EarthSmart Portable Chiller The Conair EarthSmart Portable Chillers provide self contained sources of chilled water and are available in either water or air cooled models The EarthSmart Chillers have ranges from 1 5 Hp to 30 Hp with approximate capac ities of 1 5 to 30 tons of refrigeration Pump selections are available to match most process flow and pressure requirements Conair EarthSmart Portable Chillers are designed to provide chilled fluid for industrial applications requiring 24 hour a day performance Units are totally self contained for easy economical installation All parts wetted by the process are non ferrous To operate si
18. NOTE If the optional Autofill function overfills your chiller s reservoir the Autofill timer delay will need to be adjusted See Operation section entitled Adjusting the Autofill Timer Delay By NOTE The optional To and From Process valve locations may vary depending on the model Optional Autofill hardware is available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 Installation 3 7 SEX NOTE When using a gly col mixture the use of the optional Autofill function is not recommended 3 8 Installation Filling the Chiller continued IMPORTANT When using a glycol mixture the EarthSmart Chiller control MUST be enabled for glycol usage See Operation section entitled Glycol Operation Enable Disable IMPORTANT The EarthSmart Chiller control does NOT monitor the mixture of water to glycol To fill with glycol solution 1 Mix the glycol to the proper percentage Use the table below to determine the percentage by volume of glycol needed for the process temperature in F required Mix the proper percentage of glycol with water Recommended Percentages of Glycol for Chilled Water Freeze Protection by volume Discharge water Propylene Ethylene Temperature Glycol Glycol AboveSF__ 9 30 35 40 Below 20 F Consult Factory Close the Process and From Process valves factory optional
19. Troubleshooting 6 1 6 2 Troubleshooting Before Beginning You can avoid most problems by following the recommended installation opera tion and maintenance procedures outlined in this User Guide If you have a prob lem this section will help you determine the cause and tell you how to fix it Before you begin troubleshooting Find any wiring piping and assembly diagrams that were shipped with your equipment These are the best references for correcting a problem The diagrams will note any custom features or options not covered in this User Guide Check that you have manuals for other equipment connected in the system Troubleshooting may require investigating other equipment attached to or connected with the chiller Identifying the Cause of a Problem The Troubleshooting section covers problems directly related to the operation and maintenance of the EarthSmart Chiller Types of conditions you may see include control problems not lighting or lighting and not running and alarm conditions passive or shut down When the alarm light is displayed 1 Note the alarm and press the Acknowledge Alarm button once to silence the optional audible and visual alarms and display the alarm message if still active 2 Find the error message in the diagnostics table of this Troubleshooting section Use information provided to diagnose and resolve the cause of the alarm 3 Note that after correcting the problem p
20. Annually J Cleaning the evaporator or air cooled condenser See Maintenance sections entitled Cleaning the Brazed Plate Evaporator or Water cooled Condenser and Cleaning the Air cooled Condenser C Check refrigerant piping Verify that no oil is present on fittings or cabinet Wipe clean and check charge operation of circuit To maintain the best perform ance follow the maintenance schedule and record informa tion in the Maintenance Log in Appendix B Maintenance 5 5 5 6 A IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only Maintenance Checking Electrical Connections WARNING Electrical Hazard Before performing any work on this item disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equipment AS WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should only be installed adjusted and serviced by a qualified technician personnel who is familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by a qualified
21. Open the Fill Drain valve or water supply Autofill option and the fill chiller to the recommended level of 3 4 full on the water level gauge If the chiller is overfilled the excess coolant spills out the vent tube DO NOT OVERFILL Close the Fill Drain valve Check the coolant level The coolant level drops as it begins to circulate and fill the connected plumbing Check the coolant level on the back of the chiller The coolant level shows on the water level gauge Make sure the coolant level is filled to the recommended 3 4 full level on the water level gauge Turn off the chiller and add more coolant if needed 6 Disconnect water hose from Fill Drain valve Checking the Refrigerant Charge WARNING Refrigerant hazard Only certified refrigerant technicians should examine and correct problems involving the refrigerant circuit AN CAUTION Always disconnect and lock out the main power sources before making electrical connections Electrical connections should be made only by a qualified electrical technician All EarthSmart Chillers are fully charged with R 410A refrigerant from Conair See Description section entitled Specifications EarthSmart ECW and ECA Series for required refrigerant charges QE NOTE Leaving the air cooled chiller side Check refrigerant charge while the chiller is running Check the refrigerant charge panels off for an through the sight glass Remove the bottom left side panel depending on model
22. 4 44 How to use the supervisor s password 4 45 Autotuning requirements 4 46 Autotuning procedure esee ms 4 46 Changing from fahrenheit to celsius units 4 49 Enabling Disabling display decimal point for temperature 4 50 Glycol operation 4 51 Adjusting the process variable selection 4 52 Autofill enable disable optional 4 53 Setting serial Modbus communication ID 4 54 Adjusting serial baud 4 55 Setting alarm 4 56 Adjusting the low pressure inhibit time 4 56 Adjusting the low pressure delay 4 58 Adjusting the flow switch alarm inhibit time 4 59 Adjusting the flow switch alarm delay time 4 60 Adjusting the process high alarm setpoint 4 61 Adjusting the process high alarm inhibit time 4 62 Adjusting the process high alarm delay time 4 63 Adjusting the process high temperature shutdown setpoint 4 64 Adjusting the process high temperature shutdown inhibit time 4 65 Adjusting the process high temperature shutdown delay time 4 66 Adjusting the process low alarm setpoint 4 67 Adjusting the process low alarm inh
23. Function buttons together FUNC until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual D 5 A Ez Setpoint 4 Press the Scroll button until the Process High Alarm Delay screen Screen 56 is displayed G Actual Setpoint Use the or buttons to increase or decrease the amount of time delay 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu b Operation 4 63 Adjusting the Process High Temperature Shutdown Setpoint H SA ee TIP Pressing and holding the This setting is the absolute highest temperature the chiller can reach before imme Scroll button while press diately alarming and shutting down due to abnormal operating temperatures The ing the Function button range for this setting is 50 to 100 F 10 to 37 8 C and the standard default set will increase menu navigation ting is 95 F 35 C 4 64 speed Operation To adjust the control s Process High Temperature Shutdown Setpoint 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password FUNC 2 Press the Function button to save the password entry and exit to the Main Menu Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Scre
24. L and 120 or 240 The time delay would be energized in the event of a short circuit protector trip low voltage or a break in the power sup ply to the module The time delay is not energized on opening of the high or low pressure switches Since it is not connected in the T1 T2 power circuit Solid State Components There are two major components in the protection sys tem L2 Sentronic Contactor Holding Coil Low Pressure Control Thermostat Liquid Line Solenoid Motor Protection continues 1 The protector sensors are mounted internally in the motor windings The characteristics of the sensor are such that a change in temperature causes a change in the sensor s electrical resis tance the relation between temperature and re sistance remains stable and exact so that cali bration of the protection system can be made on the basis of resistance readings 2 The control module is a sealed enclosure con taining a relay or triac transformer and several electronic components Leads from the internal motor sensors are connected to the module as shown on the wiring diagrams While the exact internal circuitry is quite complicated basically the module senses the change in resistance of the sensors As the motor temperature rises or falls the resistance also rises or falls triggering the action of the control circuit at predetermined opening and closing settings T
25. Operation section entitled Adjusting the Process Variable Selection Symptom Process Temperature Switch High tSH t NOTE This alarm automatically clears when the alarm condi tion is resolved Pressing the Alarm Acknowledgement button is not require The alarm will be present in the Alarm Log From Process Temperature Element Failure tE2F Possible cause Load too high for chiller Initial process temperature is too high User entered process fluid temperature is is too high Refrigerant charge is too low User entered Process High Passive Alarm Setpoint H AL is set too low Process High Temperature Alarm Delay and Inhibit times are set too short Hot gas Bypass valve is stuck open Damaged From Process RTD Loose or damaged RTD connection t NOTE This alarm is only passive when the chiller is controlling from To Process NOTE Passive alarms are controlled by the Process Variable Selection Screen 27 See Solution Reduce the load on the chiller Lower initial process fluid temperature Lower user entered process fluid tem perature setpoint See Operation section entitled Adjusting Setpoint Temperature See Maintenance section entitled Checking the Refrigerant Charge and Quality Increase the Process High Passive Alarm Setpoint H AL See Operation section entitled Adjusting the Process High Alarm Setpoint H AL Increase the Process High Temperat
26. button to save the password entry and exit to the 1 Menu 3 Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed FUNC Actual D 5 Ez Setpoint 4 Press the Scroll button until the Process Loop Break On Off screen Screen 68 is displayed e Actual Setpoint 5 Use the or buttons to turn the Process Loop Break on or off 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu m b Operation 4 75 ec TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation 4 76 speed Operation T V Adjusting the Process Loop Break Timer Lb t This setting is used to adjust the amount of time after the chiller s control has detected Process Loop Break until it activates a Process Loop Break Shutdown Alarm The timer will automatically reset when the chiller s actual process temper ature reaches the user entered process temperature The range for this setting is 0 to 900 seconds and the standard default setting is 10 seconds To adjust the Process Loop Break Timer 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Pas
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28. Only certified refrigerant technicians should examine and correct problems involving the refrigerant circuit Installation 3 3 t NOTE Air cooled models must be positioned so that the con denser air inlet is no warmer than 95 F 35 C and the con denser air outlet is not blocked or restricted in any way t NOTE Locate air cooled mod els away from heat producing equipment These items will affect ambient air conditions and the performance of the chiller Installation Preparing for Installation Plan the location for the chiller and prepare the area properly Position the chiller as close to the process machine as possible Place the chiller in position near the process machine so that coolant lines can be connected from the process machine to the chiller and back Chiller Process machine ES Alternate locations Make sure the area where the chiller is installed has 1 A grounded power source Check the chiller s serial tag for the correct amps voltage phase and cycle All wiring should be completed by a qualified personnel and comply with your region s electrical codes O Clearance for safe operation and maintenance Make sure there is 2 ft 60 9 cm of clearance around the chiller for proper operation After positioning lock the casters to prevent the chiller from moving For maintenance and servicing be sure there
29. Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu 6 Lower the user entered setpoint to a minimum of 20 F 11 2 C below the actual process temperature by using the or buttons 7 Press the Start button to have the chiller begin lowering the process temper ature to the user entered setpoint D 5 Ex gt 8 Press the Stop button to place the chiller in Standby mode once the actual temperature is at the user entered temperature 9 Increase the user entered temperature setpoint to a minimum of 20 F 11 2 C above the actual process temperature by using the or buttons 10 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password m4 lt gt FUNC TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation speed 11 Activate AutoTune Press and release both the Scroll and Function buttons together until the main screen of the Process Menu Screen 9 is displayed Actual Setpoint Operation 4 47 4 48 Autotuning Procedure continued o 12 Once at the Process Menu Branch press the Scroll button until the Autotune screen Screen 11 is displayed Actual Setpoint 13 Use the buttons to turn on
30. The EarthSmart Chiller s flow switch can accumulate dirt and deposits and give inaccurate water flow readouts in a poor water quality environment Periodically check the flow switch when Flow Switch Failure FSL alarms become more appar ent To check and or clean the flow switch 1 Disconnect and or lockout power to the chiller 2 Shut off the To Process and From Process valves factory optional 3 Open the Fill Drain valve Close the valve when the water level gauge on the back of the chiller reads half full 4 Remove the left side panel As view from the control continued 5 20 Maintenance Checking or Cleaning the Flow Switch continued 5 Remove the two 2 screws at the top of the switch Ensure to mark the position of the circuit selection switch located on top of the switch NO normally open Flow switch 6 Unscrew the switch from the piping with an appropriately sized wrench Note the arrow direction on the side of the switch before removing the switch must be installed back into this location 7 Inspect and clean the switch by tapping the paddle on a hard surface This will loosen debris in the upper housing so the paddle will move again and or spray with lubricant to free up moving parts or replace as necessary Replacement flow switches Apply Tefl i h itch th 1 8 pply Teflon tape or pipe dope to the switch threads and re insert are available from Conair switch into the
31. ZB95KCE ZB114KC ZB114KCE TWD 420 V 50 Hz ZB95KC ZB95KCE ZB114KC ZB114KCE TW5 200 220 V 50 Hz Compressor Lubrication The compressors can be used with different lubricants depending upon the refrigerant used See Form 93 11 for a complete list of all Emerson approved lubricants Accumulators Due to the inherent ability of scroll compressors to handle liquid refrigerant in flooded start and defrost cycle operation conditions accumulators may not be required An accumulator is required on single compressor systems when the charge limitations exceed those values listed in Table 2 On systems with defrost schemes or transient operations that allow prolonged uncontrolled liquid return to the compressor an accumulator is required unless a Condensing Temperature 20 10 10 20 30 40 50 60 F Evaporating Temperature TABLE 2 CHARGE LIMITS Charge Limits 16 Ibs Model Family 2850 58 66 76 88 95 114 KC E ZB56 68 75 92KC E amp ZB11MC E 17 165 Appendix 1 2 1 3 Appendix Compressor Module Troubleshooting continued suction header of sufficient volume to prevent liquid migration to the compressors is used Excessive liquid floodback or repeated flooded starts will dilute the oil in the compressor causing inadequate lubrication and bearing wear Proper system design will minimize liquid floodback thereby ensuring maximum compressor life
32. button ting down if there is no flow The range for this setting is 0 to 60 seconds and the will increase menu navigation standard default setting is 10 seconds speed To adjust the control s Flow Switch Alarm Inhibit Time 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main FUNC Menu 3 Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed FUNC Actual D 5 A Setpoint 4 Press the Scroll button until the Flow Switch Inhibit screen Screen 52 Ga is displayed Actual sain A 5 Use the or buttons to increase or decrease the amount of time delay button to lock in the selection and exit to the Main Menu 6 Press the Scroll button to lock in the selection or press the Function Operation 4 59 Adjusting the Flow Switch Alarm Delay Time FL d e Pressing and holding the This setting ensures that there is adequate flow through the evaporator during nor Scroll button while press mal chiller operation The time set at this screen is the time the control will wait ing the Function button before indicating an alarm and shutting down if there is no flow The range for this will increase men
33. off the Autotune 209 14 Press the Function button to start the Autotune 15 Wait for the control to complete the Autotune cycle During the Autotune several messages may be shown in the LED display NOTE In the event that an error is displayed during Autotuning see Troubleshooting section tune SetL The system is setting the measured values from the control reference tune run The system is calculating the optimal PID settings entitled Autotune Errors tune done The system has completed the Autotune cycle and has saved the PID parameters NOTE When performing an Autotune the duration for the 16 Press the Stop button once to return the chiller to normal operation chiller to complete one tune after the Autotune cycle is complete will be at least ten 10 minutes Operation Changing from Fahrenheit to Celsius Units The EarthSmart Chiller s display can be programmed to display either Fahrenheit or Celsius temperature units To select either Fahrenheit or Celsius temperature units 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main Menu 3 Press and release both the Scroll and Function buttons together until the main screen of the Setup Menu Screen 83 is displayed Se
34. 2 13 2 14 Description EarthSmart Chiller Options Alarm kit Highly visible strobe light and an alarm beacon indicate chiller alarm conditions Extended compressor warranty Warranty extension covers the compressor s only for an additional 2 years Labor refrigerant or any other chiller parts are not included during the extended warranty period Autofill Reservoir level sensor and solenoid to allow connection to city water for automatic water make up Not recommended when the chiller is using a water and Glycol mixture Process water bypass with valves Includes process water valves and a pre piped external bypass line with bypass valve for low flow high delta T processes which would limit flow through the chiller SECTION Installation Unpacking the 5 3 2 Warnings and cautions 3 3 Preparing Tor installation eins cae eee ae 3 4 Making process plumbing connections 3 5 Filling the chiller 357 Checking the refrigerant charge 3 9 Connecting the main power source 3 10 Checking electrical connections 3 12 Checking pump rotation x as gece Rx 3 13 Checking the scroll compressor 3 14 Checking the water level gauge 3 14 Adjusting the bypass valve optional 3 15 Installing alarm indicators optional 3 16 Installation 3 1 3 2 Installation Unpacking the Boxes
35. 4 68 Operation Adjusting the Process Low Alarm Delay Time L Ad This setting ensures the chiller will begin to raise the process coolant s temperature TIP Pressing and holding the during normal operation before alerting the user with a passive alarm The range Scroll button while press for this setting is 0 to 180 seconds and the standard default setting is 10 seconds ing the Function button will increase menu navigation To adjust the control s Process Low Delay Time speed 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main FUNC Menu 3 Press and release both the Scroll and Function buttons together FUNC until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual D 5 A Setpoint 4 Press the Scroll button until the Process Low Alarm Delay screen 21 Screen 62 is displayed Actual Setpoint A 5 Use the or buttons to increase or decrease the amount of time delay 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Operation 4 69 ec 4 70 TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigat
36. 43 0 2 96 Reservoir capacity gal I 10 37 9 10 37 9 25 94 6 25 94 6 25 94 6 50 189 3 75 283 9 75 283 9 75 283 9 Condenser water flow gpm l min 5 3 20 1 9 3 35 2 17 1 64 7 22 9 86 7 30 8 116 6 46 1 174 5 59 4 224 9 69 5 263 1 97 4 368 7 Dimensions inches mm A Height 40 00 1016 40 00 101656 41 1433 56 41 1433 57 78 1468 66 78 1696 76 19 1935 76 19 1935 76 19 1935 B Width 27 0 686 27 0 686 33 0 838 33 0 838 33 0 838 43 0 1092 45 50 1156 45 50 1156 45 50 1156 C Depth Approximate weight Ib kg Installed 450 204 475 216 685 311 1130 513 1240 563 1480 671 1515 687 1750 794 1985 900 Shipping 500 227 525 238 735 333 1180 535 1290 585 1530 694 1685 764 1950 885 2215 1005 Connections inches mm Process connections NPT 1 0 26 1 0 26 1 5 38 1 5 38 1 5 38 1 5 38 2 5 64 2 5 64 Condenser connections NPT 1 0 26 1 0 26 1 0 26 1 5 38 1 5 38 1 5 38 2 0 51 2 0 51 Voltages full load amps 460 3 phase 60 Hz SPECIFICATION NOTES Based on supplying 50 F 10 C water no antifreeze to process standard single pump selections maximum of 95 F 35 C ambient air and 60 Hz opera tion Adjust capacities up 2 per degree for operation above 50 F 10 C to a maximum of 65 F 18 C Adjust capacities down 2 per degree for opera tion
37. Adjusting the freeze protection shutdown alarm setpoint 2 275203 aka E EORR 5 4 80 Operation 4 3 E 7 55 ae 4 4 Basic Control Features The EarthSmart Basic Control lets you view the status of the chiller and change settings Scroll Button Increment Decrement Buttons Function Button pret seral dimene manu lisis Used to increase and or decrease Used to select different control func Pressing the Scroll button moves YOU ihe setpoint of a control function tions in conjunction with the Scroll down the list and saves changes to indi button or to save and escape menu vidual screens trees during chiller setup Dual Di ere Alpha numeric o isplay EarthSmart Chiller SX ies Codes Dual 4 digit LED screens shows actual and set Alpha numeric point process tempera characters are tures alpha numeric displayed in the alarm codes and opera setpoint screen for both process and alarm condi tion indicators Acknowledge Alarm Wh due Button mal operation 5 See Press once to silence Troubleshooting the optional audible and section for a more visual alarms Once the complete listing of alarm condition has Compressor ied E been satisfied press Bypass again to clear the alarm Status Indicator message LEDs Illuminated LED lights show the Temperature Indicator LEDs Alarm Indicator LED Start and Stop Buttons Bee erra Illuminated LEDs display
38. Do not operate the equipment at power levels other than what is specified on the the machine serial tag and data plate Pump rotation if done correctly by reversing leads at the incoming power will provide proper rotation for the rest of the three phase motors within the chiller You will not be able to determine compressor rotation unless you have refrigeration gauges To check the scroll compressor 1 Inspect the compressor If the compressor is wired incorrectly the compressor LED on the control will illuminate but the compressor will not run See Appendix J entitled Motor Protection 2 Disconnect main power to the chiller if the pump is not rotating in the proper direction swap any two incoming power wires reapply main power Wait three minutes The compressor should now be running in the proper direction See Installation section entitled Checking Pump Rotation Checking the Water Level Gauge Check the water level gauge on the back of the chiller If the coolant level below the 3 4 level see Installation section entitled Filling the Chiller Water level gauge e p Adjusting the Bypass Valve The optional Bypass valve is used when the chiller s process flow is regulated by an auxiliary piece of equipment such as a thermolator Correct water flow through the Bypass valve must be made before normal operation of the chiller can be established See Description section entitled Specifications Ea
39. EarthSmart Chiller Menu Tree continued gt bm 2 E m v m E z O I 49 50 51 52 53 54 55 56 57 58 Q NOTE Grey shaded screens denote 59 supervisor functions To access the supervisor screens see Operation sec tion entitled Using the Supervisor s Password 62 63 60 64 65 66 67 68 69 70 71 72 73 4 10 Operation EarthSmart Chiller Menu Tree continued RUNNING TIME STATUS MENU BRANCH C inn 75 76 77 78 79 A L 82 Operation 4 11 EarthSmart Chiller Menu Tree continued E U m 2 9 I 83 84 as Em un ss acr Ce er Crd 9 90 ag 5600 o2 FF PPA 95 err s 99 BQ NOTE Grey shaded screens denote supervisor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password 4 12 Operation EarthSmart Chiller Menu Tree continued TEST MENU BRANCH 104 992 Screen 102 and 109 will only be 105 983 shown when the optional Autofill hardware and axillary board are La installed Q NOTE Grey shaded screens denote supervisor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Operation 4 13 4 14 Ope
40. See Operation section entitled Adjusting Setpoint Temperature Increase Process Deviation High Setpoint See Operation section entitled Adjusting the Process Deviation High Alarm Setpoint Replace the compressor Verify that the compressor overload and wiring is installed properly See Appendix J entitled Motor Protection Check to ensure the valve is not clogged See Maintenance section entitled Checking the Hot gas Bypass Valve Have a certified refrigeration technician replace the solenoid valve Run the Autotune sequence again See Operation section entitled Autotuning Requirements and Autotuning Procedure Reload factory Autotune presets See Operation section entitled Control Function Descriptions Screens 13 14 15 and 16 Check and or replace the air filter See Maintenance section entitled Cleaning the Air cooled Condenser Passive Alarms During a passive alarm the chiller continues to operate but if ignored could lead to a condition that will shut down the chiller Q NOTE Passive alarms are controlled by the Process Variable Selection Screen 27 See Operation section entitled Adjusting the Process Variable Selection Symptom Process Deviation High continued tdH Process Deviation Low tdL Q NOTE This alarm automatically clears when the alarm condi tion is resolved Pressing the Alarm Acknowledgement button is not require The alarm will be present in th
41. and contacts the brazing flame It is important to check both the high and low sides with manifold gauges before unbrazing or in the case of assembly line repair remove refrigerant from both the high and low sides Instructions should be provided in appropriate product literature and assembly line repair areas Hi Pot Testing Copeland Scroll compressors are configured with the motor in the bottom of the shell Unlike most other hermetic compressors the scroll motor can be immersed in refrigerant when liquid is present in the shell Hi Pot test with liquid refrigerant in the shell can show higher levels of current leakage due to higher electrical conductivity of liquid refrigerant vs refrigerant vapor and oil This phenomenon can occur with any compressor when the motor is immersed in refrigerant and does not present any safety issue To lower the current leakage reading operate the system for a brief period of time redistributing the refrigerant in a more normal configuration and test again Note The solid state electronic module components and internal sensors are delicate and can be damaged by exposure to high voltage Under no circumstances should a high potential test be made at the sensor terminals or sensor leads connected to the module Damage to the sensors or module may result Motor Protection Copeland compressors using solid state protection have PTC Positive Temperature Coefficient internal sensors with an aval
42. industrial glycol mix ture and activate glycol usage within the chiller control See Operation SCREEN 20 section entitled Glycol Usage Enable Disable ra S N OFF Operation Function This screen displays the total allowable output of the Hot gas Bypass valve during one cycle Once this screen is displayed use the and buttons to change this setting The range is 0 to 90 percent A WARNING Changing this setting will effect chiller performance This screen displays the Process Setpoint High Limit This screen sets the maximum temperature setpoint of the chiller Once this screen is displayed use the and buttons to change this setting The range is 20 to 70 F 6 7 to 21 1 C This screen displays the Process Setpoint Low Limit This screen sets the minimum temperature setpoint of the chiller Once this screen is displayed use the and buttons to change this setting The range is 20 to 70 F 6 7 to 21 1 C This screen displays the Ramp to Setpoint On Off Turning on this setting will allow temperature ramping to setpoint by the rate set on Screen 21 Pressing the but ton on this screen will turn on the Ramp to Setpoint pressing the will turn off the Ramp to Setpoint Control Function Descriptions continued Screen n m s 2 ES ra r ra H AF d n n zx 5 2 2 f N N Function This sc
43. s reservoir A float level switch is used to sense the water level When the switch contacts close an input signal is sent to the control board to open the water makeup solenoid valve which allows water to enter the chiller s reservoir When the water level opens the switch the control will wait until the Autofill Delay Time AF d has expired before shutting off the valve If the float switch remains open for more than the set duration of the Autofill Timer the con trol will display a Level Switch High Alarm LSH and immediately shut off the valve If the chiller s reservoir has not been filled before the Autofill Timer has expired re adjust the Autofill Timer or press the Alarm Acknowledgement button to restart the timer To install the Autofill function 1 Disconnect and lockout power to the chiller 2 Shut of the Process and From Process valves factory optional continued Installing Autofill optional continued 3 Remove the chiller s left and right side panels 4 Locate the 1 2 inch reservoir plugs on the top left corner and right side of the reservoir The chiller s reservoir is located in the bottom portion of the chiller s cabinet and towards the back 5 Remove the Autofill knockout on the back of the chiller above the water level gauge 6 Connect the brass piping to the In side of the solenoid valve by using Teflon tape or pipe dope Do not over tighten Solenoid
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45. 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main Menu 3 Press and release both the Scroll and Function buttons together until the main screen of the Setup Menu Screen 82 is displayed Actual Setpoint 4 Press the Scroll button until the Load Default screen Screen 95 is displayed Actual Setpoint 5 Use the or buttons to turn the Load Default on or off 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu 7 Error code 0297 will be shown in the chiller s display This is normal after resetting factory defaults 8 Restart the chiller s control to resume normal operation SECTION Troubleshooting Before 6 2 Identifying the cause of a problem 6 2 A few words of caution 6 3 TROUBLESHOOTING Chiller problems 2 RR RR 6 4 Autotuning errors 6 6 Passive 5 6 8 Shut down alarms 6 13 Additional alarms 6 20 Replacing the 6 22 Removing pump components 6 23 Replacing the contactor 6 24 cu 4 22 20 gt
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47. Actual Setpoint Use the or buttons to increase or decrease the amount of time delay Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Adjusting the Process Low Alarm Setpoint L AL This setting ensures the chiller does not drop below the minimum operational tem _ TIP Pressing and holding the perature and alerts the user with a passive alarm to abnormal operating tempera Scroll button while press tures The range for this setting is 35 to 50 F 1 7 to 10 C or if a glycol mix ing the Function button ture is being used 15 to 50 F 9 4 to 10 C and the standard default setting is will increase menu navigation 40 F 4 4 C speed To adjust the control s Process Low Alarm Setpoint 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main FUNC Menu 3 Press and release both the Scroll and Function buttons together d FUNC until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual af 2 Setpoint 4 Press the Scroll button until the Process Low Alarm Setpoint screen Screen 60 is displayed Actual Setpoint 5 Use the or buttons to increase or decrease th
48. Appendix B entitled Maintenance Log Use this maintenance schedule as a guide You may need to shorten the time of the maintenance schedule depending on how often you use the chiller Among the fea tures that require preventative maintenance are The refrigerant system Electrical cables terminals and control lights The condenser condenser filter strainer inlets Caster locks Temperature and pressure readings Process fluid level Energy efficiency Evaporator filter strainer at evaporator and condenser inlets Cooling water treatment system if used Warnings and Cautions N WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should only be installed adjusted and serviced by a qualified technician who is familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by a qualified electrical technician in accordance with electrical codes in your region A WARNING Electrical Hazard Before performing any work on this item disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equip ment A CAUTION Hot Surfaces Always protect yourself from hot surfaces when work
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50. If an accumulator must be used an oil return orifice size in the range of 0 040 0 075 inches 1 1 9 mm is recommended A large area protective screen no finer than 30 x 30 mesh 0 6 mm openings is required to protect this small orifice from plugging with system debris Tests have shown that a small screen with a fine mesh can easily become plugged causing oil starvation to the compressor bearings Screens The use of screens finer than 30 x 30 mesh 0 6 mm openings anywhere in the system is not recommended Field experience has shown that finer mesh screens used to protect thermal expansion valves capillary tubes or accumulators can become temporarily or permanently plugged with normal system debris and block the flow of either oil or refrigerant to the compressor Such blockage can result in compressor failure TABLE 3A CONDUIT READY HEATER BOX KITS Model Number Kit Number ZB50 ZB58 ZB66 998 7029 00 ZB76 ZB88 ZB95 ZB114 ZB56 ZB68 ZB75 ZB92 ZB11M 998 7015 00 Advanced Scroll Temperature Protection ASTP After extensive research and trials Emerson Climate Technologies found a way to install a Therm O Disc temperature sensitive snap disc in the ZB50 2858 2866 2876 2895 2888 and 28114 scroll compressors This acts to protect compressor from use m iu il nU Wt in Advanced Scroll Temperature Protection Compressor May Stop Pumping Wi
51. Menu Branch See Operation section entitled Using Supervisor s Password Press the Function button to save the password entry and exit to the Main Menu Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual Setpoint Press the Scroll button until the Process High Alarm Inhibit screen Screen 55 is displayed Actual Setpoint Use the or buttons to increase or decrease the amount of time delay Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Adjusting the Process High Alarm Delay Time HA d This setting ensures the chiller will have enough time to lower the process ee TIP Pressing and holding the coolant s temperature during normal operation before alerting the user with a pas Scroll button while press sive alarm The range for this setting is 0 to 60 seconds and the standard default ing the Function button setting is 5 seconds will increase menu navigation speed To adjust the control s Process High Alarm Delay Time 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main FUNC Menu 3 Press and release both the Scroll and
52. Sufficient isolation is provided to prevent vibration from being transmitted to the mounting structure This mounting arrangement is recommended for multiple compressor rack installations See Figure 4 for a detail for this mounting system Figure 4 7 5 15 HP Rack Mounting 102 0119 00 WASHER NZA z 027 0115 00 NN 2 RUBBER PAD 027 0280 00 STEEL SPACER KIT 527 0158 00 Note The use of standard soft grommets is not recommended for our refrigeration scroll rack installations These softer mounts allow for excessive movement that will result in tube breakage unless the entire system is properly designed Connection Fittings There are various connection fittings available for Copeland Scroll refrigeration compressors The various options are shown in Table 8 Three Phase Scroll Compressors Directional Dependents Scroll compressors are directional dependent i e they will compress in one rotational direction only Three phase Scrolls will rotate in either direction depending on power phasing Since there is a 50 50 chance of connected power being backwards contractors should be warned of this Appropriate instructions or notices should be provided by the OEM To eliminate the possibility of reverse rotation a Copeland Phase Control line monitor P N 085 0160 00 or other phase monitor is recommended Verification of proper rotation can be made by observing that the sucti
53. Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main FUNC Menu 3 Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed Che FUNC Actual D 5 A Setpoint 4 Press the Scroll button until the Process High Alarm Setpoint screen Screen 54 is displayed G Actual Setpoint 5 Use the or buttons to increase or decrease the temperature setting 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu 4 Operation 4 61 ec TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation 4 62 speed Operation Adjusting the Process High Alarm Inhibit Time This setting ensures the chiller will have enough time to lower the process coolant s temperature during initial chiller start up before alerting the user with a passive alarm The range for this setting is 0 to 300 seconds and the standard default setting is 10 seconds To adjust the control s Process High Alarm Inhibit Time 1 FUNC 2 FUNC Ig A 4 Enter the Supervisor s password within Setup
54. Temperature This document is provided courtesy of Emerson Climate Technologies This document may be updated regularly Go to www EmersonClimate com to check for the most recent materials Compressor Module Troubleshooting continued Figure 1C ZB95KCE amp ZB114KCE Application Envelope for R404A R507 HT Applications 7 15Hp F 65 F Return Gas 20 F SH Condensing Temperature 3 o 20 10 o 10 20 40 50 60 F Evaporating Temperature Figure 1D ZB KC excluding ZB95KC amp ZB114KC Application Envelope for R22 HT Applications 7 15Hp F 65 F Return Gas 20 F Min SH 150 I 5 140 5 430 o a 120 E 110 F 100 70 5 6o V so 20 10 10 20 5o 60 F Evaporating Temperature Figure 1E ZB95KC amp ZB114KC Application Envelope for R22 HT Applications 7 15Hp 20 F SH a 83 o N a 2 o Figure 1F ZB KCE Application Envelope for R134A HT Applications 7 15Hp 20 F Superheat 170 22 8 140 120 3 Condensing Temperatur 388 10 o 170 z0 Evaporating Temperature F 30 40 50 Voltage Frequency Restrictions Due to inadequate cooling from refrigerant flow through the compressor the following 50 Hz applications are not approved ZB95KC
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56. adjust the control s Process Deviation High Alarm Delay Time 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main FUNC Menu 3 Press and release both the Scroll and Function buttons together FUNC until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual D 5 Ez Setpoint 4 Press the Scroll button until the Process Deviation High Alarm Delay screen Screen 66 is displayed Setpoint 5 Use the or buttons to increase or decrease the amount of time delay 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Operation 4 73 ec TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation 4 74 speed Operation Adjusting the Process Deviation Low Shutdown Alarm Setpoint dL L This setting is used to activate a Process Deviation Low Alarm and shuts down the chiller when the actual process temperature drops below the setting at this screen The range for this setting is 0 to 80 0 to 44 9 C below the user entered setpoint and the standard default setting is deliberately set at 80 F 44 9 C To adjust the contro
57. are less than 2500 ohms remove leads from the M1 M2 contacts and jumper together CAUTION Compressor should start at this time HOWEVER DO NOT LEAVE JUMPER IN PLACE FOR NORMAL SYSTEM OPERATIONS THE JUMPER IS USED FOR DIAGNOSTIC PURPOSES ONLY Go to Compressor Supply Troubleshooting Voltage Compressor Voltage Supply Troubleshooting e Remove phase sensing leads from the module from L1 L2 L3 Use a voltmeter to measure the incoming 3 phase voltage on L1 L2 L3 WARNING L1 L2 L3 could be at a potential up to 600VAC Ensure proper voltage on each phase Remove power to the module for a minimum of 5 seconds to reset and replace all wire leads Re energize the module If the M1 M2 contacts are open with proper voltage to T1 T2 L1 L2 L3 and proper resistance to S1 S2 then the module is faulty and should be replaced Compressor Module Troubleshooting continued Compressor Mounting Compressor mounting must be selected based on application Consideration must be given to sound reduction tubing reliability Some tubing geometry or shock loops may be required to reduce vibration transferred from the compressor to external tubing Mounting for Rack Systems Specially designed steel spacers and rubber isolator pads are available for our refrigeration scroll 7 5 15 HP scroll rack applications This mounting arrangement limits the compressors motion thereby minimizing potential problems of excessive tubing stress
58. button until the Compressor Cycles per Hour Alarm J Setpoint screen Screen 72 is displayed Actual Setpoint A 5 Use the or buttons to increase or decrease the amount of cycles per hour 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Operation 4 79 Scroll button while press ing the Function button Adjusting the Freeze Protection Shutdown Alarm Setpoint FP ee TIP Pressing and holding the This setting is used to adjust the minimum low temperature setpoint before the chiller will immediately shut down to avoid freezing of the process fluid The range for this setting is 35 to 50 F 1 7 to 10 C or if a glycol mixture is used will increase menu navigation 15 to 50 F 9 4 to 10 C The standard default setting is 41 F 5 C To adjust the Freeze Protection Shutdown Alarm Setpoint 1 mz speed FUNC 4 80 Operation G lt gt Enter Supervisor s password within Setup Menu Branch See Operation section entitled Using Supervisor s Password Press the Function button to save the password entry and exit to the Main Menu Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual Setpoint Press the Scroll button until the Freeze Protect
59. down the or buttons will cause the setpoint to ramp up or ramp down at a faster rate The temperature setpoint will be automatically saved to the 5 controller The chiller will begin to raise or lower the process temperature according to your setting EarthSmart Chiller SX Actual Setpoint oc Compresso 5 Bypass Setpoint Adjustment Buttons 4 44 Operation How to Use the Supervisor s amp NOTE Entering the password is P a S S 0 r d required to access all shaded Th isor d b d bef ak h screens See Operation section e supervisor s password must be entered before you can use or make changes to entitled EarthSmart Chiller some screens on the EarthSmart Chiller s control Ment Thee To enter the supervisor password 1 Press and release both the Scroll and Function buttons together i FUNC until the main screen of the Setup Menu Screen 83 is displayed Actual ec TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation speed Setpoint 2 Press the Scroll button until the Password screen Screen 84 is j displayed D 5 Ez gt Setpoint 3 Use the or buttons to increase or decrease the number in the lower A screen Holding down the or buttons will cause the number to ramp up or down at a faster rate The default supervisory password is 210 En
60. extended period of and check the sight glass time will cause the chiller to shut down O Under full load conditions the refrigerant should be clear no bubbles due to a High Pressure alarm O Under low load conditions when the Hot gas Bypass valve is operating bubbles may be visible in the sight glass This is normal If the charge is low and the unit is under warranty contact Conair service Otherwise have a local certified refrigeration technician add R 410A refrigerant to the system Sight glass Installation 3 9 N IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only 3 10 Installation Connecting the Main Power Source AX WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should only be installed adjusted and serviced by a qualified technician who is familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by a qualified electri cal technician in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the machine data plate N WARNING Electrical hazard Before performing any work on this equipment disconne
61. in degree Celsius Some special registers contain bit ori ented information such as alarms In order to read these registers correctly the Modbus master or PLC embedded controller etc should perform a bit mask to the incoming integer value to strip the information required Some critical parameter addresses are read only A Quick Block grouping that was created pertains all of the most commonly used registers if required using this block can increase network speed Optional Modbus communica tions kits are available for field retrofit Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 Front of DB 9 Connector Outside of EarthSmart Electrical Panel NOTE See Operation section entitled Setting Serial Modbus Communication ID and Adjusting Serial Baud Rate to configure the serial Modbus connection for the EarthSmart Chiller Appendix K 1 Optional Ethernet communica tions kits are available for field retrofit Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 K 2 Appendix EarthSmart Chiller Ethernet Communications The EarthSmart Chiller has the capability of communicating on a plant wide Ethernet communication network Modbus TCP is a protocol that takes the basic serial Modbus command set and applies it to the Ethernet standard via TCP IP protocol This is useful for applications that require commun
62. is displayed use the and buttons to change this setting This is the Process Integral screen Itis used to slowly adjust the position of the proportional gain setting to eliminate off set error Use the and buttons to change this setting This is the Process Derivative screen Itis used to change how fast or slow the con trol will react to load changes Use the and buttons to change this setting This screen displays the duration of the Hot gas Bypass valve cycle Once this screen is displayed use the and but tons to change this setting Conair recom mends a 5 to 10 second setting The range of this setting is 0 to 120 seconds S NOTE Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password S NOTE A cycle includes the amount of on time and off time For exam ple a 10 second cycle time equals 5 seconds on and 5 seconds off of the Hot gas Bypass valve Operation 4 17 Control Function Descriptions Screen SCREEN 17 NOTE Grey shaded 5 NOTE Settings for 4 18 screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password SCREEN 18 Hi L N Screens 18 and 19 can not overlap o 2 Lo L WARNING To operate below 40 F 4 4 C you must use an
63. listed below ECW Series Chiller ECA Series Chiller Fan Cycling Switch Cut In NA 450 psig Pressure Switch High 550 psig 38 bar 550 psig 38 bar Pressure Switch Low 85 psig 5 8 bar 85 psig 5 8 bar Relief Valve 650 psig 44 8 bar 650 psig 44 8 bar Pressure switch low settings for the EarthSmart Chillers are based on 40 F 4 4 C leaving water temperature For leaving water temperatures between 20 F and 39 F 6 7 C and 3 8 C the pressure switch low setting is 50 psig 3 4 bar NA Fan Cycling Switch Cut out NA 320 psig Resetting the High Pressure Switch WARNING Refrigerant hazard Only certified refrigerant technicians should examine and correct problems involving the refrigerant circuit A CAUTION Always disconnect and lock out the main power sources before making electrical connections Electrical connections should be made only by a qualified electrical technician The high refrigeration safety pressure switch shuts off the compressor immediately when the high refrigeration pressure reaches 550 PSI 37 9 bar without going through pump down during a low pressure cycle If the high pressure switch trips it must be manually reset by pressing the Reset button on the switch The compressor can start immediately when this is reset so caution should be exercised To reset the high refrigeration safety switch 1 Be sure the main power is disconnected and the chiller is locked out Always disconne
64. or press the Function button to lock in the selection and exit to the Main Menu Operation 4 53 ec TIP Pressing and holding the Setting Serial Modbus Communication ID Scroll button while press The EarthSmart Chiller can be configured to communicate over a Modbus net ing the Function button work An optional kit must be installed for the chiller to use the Modbus network will increase menu navigation This optional kit will include a communications daughter card internal connecting speed harness and a panel mount DB 9 terminal See Appendix K entitled EarthSmart Chiller Modbus Communications for assigning Modbus address settings Q NOTE Ethernet communica tions will require configuration To set the EarthSmart Chiller s Modbus address through the ethernet control 4 54 software 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main Menu d FUNC 3 Press and release both the Scroll and Function buttons together until the main screen of the Setup Menu Screen 83 is displayed Actual Operation Setpoint 6 4 Press the Scroll button until the Communications screen Screen 89 is displayed Actual A 5 Use the or buttons to increase or decrease the address number assignment See Ap
65. range for this setting is 0 to 900 seconds and the standard default setting is 600 will increase menu navigation seconds speed To adjust the control s Process Deviation High Alarm Inhibit Time 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main FUNC Menu 3 Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed z Actual Setpoint 2 4 Press the Scroll button until the Process Deviation High Alarm Inhibit screen Screen 65 is displayed Actual Setpoint v 5 Use the or buttons to increase or decrease the amount of time delay 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu 4 72 Operation Adjusting the Process Deviation High Alarm Delay Time dE d This setting ensures the chiller will begin to lower the process coolant s tempera e TIP Pressing and holding the ture during normal operation before alerting the user with a passive alarm The Scroll button while press range for this setting is 0 to 900 seconds and the standard default setting is 30 ing the Function button seconds will increase menu navigation speed To
66. range is 0 to 900 seconds This screen displays the Process Deviation High Alarm Delay Time This setting is used to adjust the amount of time after the chiller has detected a Process Deviation High Alarm that its input will be ignored This is used so that the chiller s tempera ture can resume normal operating condi tions Use the and buttons to change this setting The range is 0 to 900 seconds This screen displays the Process Deviation Low Shutdown Alarm Setpoint This set ting is the maximum deviation below the user entered low temperature setpoint Screen 19 When the coolant falls below the setpoint by the amount set at this screen the chiller automatically shuts down to avoid freeze damage to the evapo rator or process material Use the and buttons to change this setting The range is 0 to 80 F 0 to 44 9 C This screen displays the Process Loop Break On Off This setting can be used when the process temperature is higher or lower than the actual temperature setpoint but never exceeds the Process Deviation High or Low setpoints When enabled this setting will activate a Process Loop Break Alarm This setting will always be deacti vated when the Ramp to setting has been enabled Use the and buttons to turn this setting on or off Control Function Descriptions continued Screen Lb t o o Q s e E E 2 2 ON e 5 ALS AFt n Ww es
67. selection to protect against freezing of the coolant From Process and Average process variable selec tions are less accurate and promote nuisance alarms Autofill Enable Disable optiona The optional Autofill feature automatically fills the chiller s internal reservoir An optional Conair supplied level switch located inside the reservoir indicates whether the chiller requires more process coolant or when it has been filled to capacity See Appendix G entitled Installing Autofill optional ec TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation speed To enable disable the Autofill option IMPORTANT The optional Autofill function will not 1 Enter the Supervisor s password within the Setup Menu Branch See operate without the level Operation section entitled Using Supervisor s Password switch and axillary board 2 Press the Function button to save the password entry and exit to the Main FUNC Menu 3 Press and release both the Scroll and Function buttons together until the main screen of the Setup Menu Screen 83 is displayed e ES FUNC Actual D 5 Setpoint 4 Press the Scroll button until the Autofill screen Screen 87 is displayed C Actual Setpoint 5 Use the or buttons to enable or disable the Autofill option 6 Press the Scroll button to lock in the selection
68. tector trip are from 2700 4500 ohms The three sen sors have one lead connected together to form a com mon connection point C The other leads are connected to a separate terminals S1 S2 S3 2 Low Voltage Cut Out a 120 VAC module Cut Out Voltage 85 4 5 Volts in normal ambient Cut In Voltage 4 Volts above cut out Low Voltage response delay 0 2 15 seconds Li 120V 240 High Low Pressure Pressure Safety Safety Thermostat Sentronic Oil Pressure Typical Line Voltage Circuit Without Pumpdown Figure 6 b 208 240 VAC module Cut Out Voltage 170 8 Volts in normal ambient Cut In Voltage 5 Volts above cut out c Dual voltage TI 31AA module 120VAC or 208 240 VAC Depending on the voltage supplied 120 VAC or 208 240 VAC the low voltage cut out of the 31AA is the same as either 2 a or 2 b d Dual voltage TI 41AA module 120 208 240 VAC depending on the voltage supplied 120 VAC or 208 240 VAC low voltage cut out of the 41 15 as follows i 120 module cut out voltage 85 5 5 volts in normal ambient cut in voltage 3 volts above cut out Low voltage response delay 0 2 15 secs ii 280 240 VAC module cut out voltage 170 10 volts in normal ambient cut in volt age 3 volts above cut out voltage Note Normal ambient conditions 59 F to 89 6 F 15 C to 32 C 3 Off cycle timer 120 second 15 with normal ambient 4 The output device the triac TI 15AA or t
69. tem perature setpoint See Operation section entitled Adjusting Setpoint Temperature See Maintenance section entitled Checking the Refrigerant Charge and Quality Increase the Process High Passive Alarm Setpoint H AL See Operation section entitled Adjusting the Process High Alarm Setpoint H AL Increase the Process High Temperature Alarm Delay and Inhibit times See Operation sections entitled Adjusting the Process High Inhibit Time HA i and Adjusting the Process High Delay Time HA d Troubleshooting 6 17 6 18 Shut Down Alarms ontinuea The chiller has automatically shut down because it has detected a serious problem that could damage your material or chiller Symptom Process Temperature Deviation Low Shutdown tdLL t NOTE This setting will not be used unless critical for your particular application Troubleshooting Possible cause Load too low for chiller Damaged or clogged Hot gas Bypass valve Compressor cut out setpoint is set too low Process Deviation Low Setpoint is set too high Process Low Alarm Inhibit Time set too low Process Low Alarm Delay Time set too low Load too low for chiller Initial process temperature is too low User entered process fluid temperature too low Glycol usage not enabled Water flow is too low Faulty compressor contactor Improperly adjusted Process Deviation Low Shutdown Alarm setpoint Solution Increase
70. temperature envi ronment Reduce the temperature of the condenser water Shut Down Alarms ontinuea The chiller has automatically shut down because it has detected a serious problem that could damage your material or chiller Symptom Refrigeration Pressure Switch Low PSL Possible cause No or low flow with a failed flow switch and a faulty RTD The evaporator is fouled Evaporator frozen Improper glycol mixture Faulty TXV solenoid valve Refrigerant leak Condenser air or water too cold Improper fan cycling pressure switch setting Solution Check optional To Process and From Process valves to see if they are open Check flow switch and RTD Replace as necessary See Troubleshooting section entitled Replacing the RTD and Maintenance section entitled Checking or Cleaning the Flow Switch Clean evaporator See Maintenance sec tion entitled Cleaning the Evaporator or Water cooled Condenser Check the flow switch RTD and low temperature cutout on control Replace as necessary See Troubleshooting section entitled Replacing the RTD and Maintenance section entitled Checking or Cleaning the Flow Switch Re adjust glycol mixture see Installation section entitled Filling the Chiller Check wiring voltage coil and relay see electrical drawings replace as needed Check for oil in chiller cabinet and bub bles in refrigerant sight glass See Maintenance section entitled
71. test personnel must be alert to this feature since it is possible in checking the compressor or system power may be applied disconnected and reapplied in less than two minutes In such case the time delay feature will prevent operation until the time delay has expired and this may be misinterpreted by service personnel as a module malfunction Li Electronic Motor Protector High Pressure Safety Schematic Control Circuit Continuous Pumpdown with off Cycle Refrigerant Control Figure 7 If the system design is such that the operating con trols are wired to the module power circuit the time delay will provide two minute short cycle protection If the system refrigerant charge is small enough so that a pump down control circuit is not required the con trol devices may be mounted in the line circuit as in Figure 6 This provides the maximum electrical pro tection against short cycling or contactor chattering With larger refrigerant charges see AE Bulletin 22 1182 a pumpdown system is essential to protect the compressor against liquid refrigerant Figure 7 shows a typical circuit with the liquid line solenoid wired through the protectors to prevent refrigerant migration in the event of a protector trip This circuit uses the Sentronic oil pressure switch with its jumper from L to 2 removed so the Sentronic control switch L to M can be isolated from its control circuit power connections
72. the Process connection returning to the process left side as view from the control panel 2 4 Description How it Works EarthSmart ECW Series Water cooled Models continued Refrigerant circulation 1 The evaporator extracts heat from the process fluid causing the refrigerant to vaporize evaporate into a gas 2 Vaporized refrigerant travels from the evapora tor to the compressor where the low pressure vapor is compressed into a high pressure high temperature vapor The high pressure high temperature vapor from the compressor travels to the condenser The high pressure high temperature vapor travels from the condenser to the receiver Water tower or city water removes heat from the vapor condensing it to a high pressure high temperature liquid High pressure high temperature liquid is metered back to the evaporator by the expansion valve TXV changing it to a low pressure low temperature liquid vapor
73. the load on the chiller Have a certified refrigeration technician replace the solenoid valve Adjust the compressor cut out setpoint See Operation section entitled Control Screen Descriptions Screen 24 Adjust the Process Deviation Low Alarm setpoint See Operation section entitled Adjusting the Process Deviation Low Alarm setpoint dE L Adjust the Process Low Inhibit Time setpoint See Operation section entitled Adjusting the Process Low Alarm Inhibit Time L Ai Adjust the Process Low Alarm Delay Time setpoint See Operation section entitled Adjusting the Process Low Alarm Delay Time L Ad Increase the load on the chiller Increase initial process fluid tempera ture Increase user entered process tempera ture setpoint See Operation section enti tled Adjusting Setpoint Temperature Enable glycol usage see Operation section entitled Glycol Operation Enable Disable Adjust water flow to your specific chiller model See Description section entitled Specifications EarthSmart ECW and ECW Series Verify that the compressor contactor disengages in Stop mode replace as necessary Re adjust setpoint See Operation section entitled Adjusting the Process Deviation Low Shutdown Alarm Setpoint dL L Shut Down Alarms continued The chiller has automatically shut down because it has detected a serious problem that could damage your material or chiller Symptom Compressor Cycles Per Hour Exc
74. the process fluid providing consis tent chiller temperatures If the HGBP valve is closed 100 cooling capacity is used IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in to reduce or maintain temperature the User Guide are intended to be representative only To check the Hot gas Bypass valve s functionality 1 Remove the left side panel As viewed from the control 5 14 Maintenance continued Checking the Hot gas Bypass Valve Operation continued 2 Locate the TXV and follow the refrigerant piping to the evaporator The Hot gas Bypass line is the piping running down from the upper portion of the chiller s cabinet between the evaporator and TXV 3 During operation the bypass LED on the chiller s control panel will pulse on and off indicating that the valve is being energized There should also be a click from the valve and refrigerant flowing hissing sound to the evaporator 4 Measure the temperature of the Hot gas Bypass line as the valve is energized If the valve is functioning properly there should be a noted temperature rise from when the valve is off to when it is energized 5 Verify that the Hot gas Bypass valve coil is functioning correctly and that power is reaching the coil when the bypass LED is energized if no sign of refrigerant flow or temperature change has been detected See the chiller s electri cal
75. valve inlet Brass piping 7 Connect one 1 of the hose barbs to the Out side of the solenoid by using Teflon tape or pipe dope Do not over tighten Solenoid valve outlet Hose barb continued Appendix G 2 Installing Autofill optional continued 8 Connect the brass piping to the outlet of the bulkhead by using Teflon tape or pipe dope Do not over tighten Install the gasket on the thread side of the bulkhead Bulkhead Bulkhead gasket 9 Connect the hosing to the hose barb secure with a hose clamp 10 Insert the solenoid assembly through the knock out on the back of the chiller secure it with the left handed retaining nut Do not over tighten Left handed retaining nut G 3 Appendix continued Installing Autofill optional continued 11 Connect one 1 hose barb to the 90 street pipe by using Teflon tape or pipe dope Do not over tighten 90 street pipe Hose barb 12 Connect the 90 street pipe assembly to the chiller s reservoir by using Teflon tape or pipe dope Do not over tighten 90 street Reservoir pipe 13 Connect the loose end of pipe from the solenoid assembly to the 90 street pipe assembly by securing the connection with a clamp Do not over tighten continued Appendix G 4 Installing Autofill optional continued 14 Connect the solenoid plug to the Autofill 13PL receptical The Autofill plug is coiled near the lower bac
76. 00W x 20 2750W 20 T1 T2 interrupt for T1 T2 interrupt for T1 T2 interrupt for T1 T2 interrupt for minimum of 5 sec minimum of 5 sec minimum of 5 sec minimum of 5 sec L1 L2 L3 Phase Monitoring Non Phase Sensing Non Phase Sensing Non Phase Sensing Non Phase Sensing Non Phase Sensing 3 AC 50 60Hz Non Phase Sensing 120V to 632V Non Phase Sensing Non Phase Sensing 5 min delay before Non Phase Sensing restart attempt Non Phase Sensing Non Phase Sensing After 10 module trips Non Phase Sensing Non Phase Sensing Non Phase Sensing T1 T2 interrupt for Non Phase Sensing minimum of 5 sec Appendix 1 6 1 7 Appendix Compressor Module Troubleshooting continued of 9 VDC for checking do not attempt to check continuity through the sensors with any other type of instrument Any external voltage or current may cause damage requiring compressor replacement a During normal operation this resistance value should read less than 4500 ohms 20 b If the M1 M2 contacts are open the measured 51 52 value is above 2750 ohms 20 and the compressor has been tripped less then 30 minutes then the module is functioning properly e If the S1 S2 wire leads read less than 2750 ohms 20 and the M1 M2 contacts are open reset the module by removing the power to T1 T2 for a minimum of 5 seconds e Replace all wire leads and use a voltmeter to verify the M1 M2 contacts are closed e Ifthe M1 M2 contacts remain open and S1 S2
77. 1 93 45 0 3 10 Reservoir capacity gal I 10 37 9 10 37 9 25 94 6 25 94 6 25 94 6 50 189 3 75 283 9 75 283 9 75 283 9 Condenser fan qty fan Hp KW each 1 1 15 0 86 1 1 15 0 86 1 1 5 1 10 2 1 4 1 05 2 1 4 1 05 1 3 0 2 25 2 1 4 1 05 2 3 0 2 25 2 3 0 2 25 Dimensions inches mm Height 54 63 1388 54 63 1388 74 06 1881 81 34 2066 2066 2195 2303 88 56 2250 88 56 2250 B Width 27 00 686 27 0 686 33 0 838 33 0 838 0 838 1092 1156 45 50 1156 45 50 1156 C Depth 46 88 1191 46 91 1192 51 88 1318 63 50 1613 1613 1613 1927 76 09 1933 76 09 1933 Connections inches mm Process connections NPT 1 0 25 1 0 25 1 5 38 1 5 38 15 5 64 2 5 64 2 5 64 Approximate weight Ib kg Installed 485 220 535 243 1050 476 1540 699 1680 762 1850 839 1905 864 2113 958 2320 1052 Shipped 535 243 580 263 1100 499 1590 721 1730 785 1900 862 2075 941 2313 1049 2550 1157 Voltages full load amps 460 3 phase 60 Hz SPECIFICATION NOTES Based on 50 F 10 C supply water no antifreeze to the process standard single pump selections a maximum of 95 F 35 C ambient air and 60 Hz oper ation Adjust capacities up 2 per degree for operation above 50 F 10 C to a maximum of 65 F 18 C Adjust capacities down 2 per degree of opera tion below 50 F 10 C to
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79. 40 vac without the use of a jumper connec tion See Figures 1 and 2 These modules utilize a transformer power supply design which simplifies in stallation by eliminating the need to use a jumper wire to select between a 120v or 240v power supply This upgrade also yields a significant improvement over the old design in its ability to compensate for large voltage fluctuation spikes that could occur In the past there have been in certain situations problems with nuisance trip ping of the module due to motor noise generation in specific locations Through extensive laboratory and field testing the nuisance tripping has been eliminated thus providing reliable service The 31AA requires a jumper connection to accept either 120 vac or 208 240 vac See Figures 3 and 4 All other modules required two models one for 120VAC and another for a 208 240 VAC power source Control Specification for Kriwan Sensors and Kriwan INT369R Module After 2004 The resistance of the sensor will vary from 30 ohms cold to 20 000 ohms hot Reset values after a pro tector trip are from 2700 4500 ohms The three sen sors have one lead connected together to form a com mon connection point C The other leads are con nected to a separate terminal S1 S2 and S3 The modules can time out from the follow conditions e High Motor Temperature e Low Line Voltage to Module Power Outage Module Electrical Connections See Figure 5 M1 M2 C
80. 6 Appendix Motor Protection continued an ohmmeter Any external voltage or current applied to the sensors may cause damage requir ing compressor replacement c Measure the resistance from each sensor termi nal to the common terminal The resistance should be in the following range 30 ohms Kriwan post year 2004 500 ohms pre year 2004 sensors cold to 20 000 ohms hot compressor tripped Resistance readings in this range indicate the sen Sors are good Aresistance approaching zero in dicates a short a resistance approaching infinity indicates an open connection Proper operation of the control system is dependent on a continu ous parallel circuit through all three sensors with no individual resistance reading higher than 10 000 ohms On initial start up and after any module trip due to high temperatures the resis tance of the sensors must be below the module reset point before the module circuit will close Reset values are 2700 4500 ohms The dotted sensor leads represent internal motor connections with sensors Circuit Resistor M2 Module Pala lt gt ircui Terminal Board M eine T2 Sensors 535251 Electronic Module Showing Sensor Connections Emergency Bypass of Damaged Solid State Sensor Figure 9 5 Ifthe sensors have the proper resistance and are below 2700 ohms the compressor wil
81. 999 1495 3 E 5 t Ej E z 9 z The rate at which values and parameters Contact Conair Service Writes are being stored to the chiller s long term memory in EEPROM exceeds ten err writes per second 1496 Troubleshooting 6 21 N IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only t NOTE These connections may vary depending on the model you have purchased Be sure to see the labeling on your particular unit Replacement RTDs are avail able from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 6 22 Troubleshooting Replacing the RTD To replace the RTD 1 Disconnect and lockout power to the chiller 2 Disconnect the To Process tubing from the Process connection O o Fill Drain valve From Process inlet To Process outlet 3 Open the Drain Fill valve and drain water from the unit so the water level is lower than the RTD 4 Open the left side of the chiller As viewed from the control 5 Disconnect the RTD wiring from the back of the electrical enclosure Refer to the wiring diagram 6 Remove the RTD Loosen the compression nut to slide the RTD out of the evaporator 7 Install the new RTD The new RTD should be inserted in the evaporator so that the tip is ex
82. C Maximum time allowed for an Auto tune cycle 15 minutes has expired Listed below are possible errors that may be displayed when attempting an Autotune cycle Solution Have a certified refrigeration technician replace the valve Exit the Autotune cycle and restart with a lower process temperature setpoint See Operation section entitled Adjusting Setpoint Temperature Exit the Autotune cycle and restart Autotuning Errors continued Listed below are possible errors that may be displayed when attempting an Autotune cycle Symptom tune err6 Possible cause The Autotune failed to calculate a meaningful response of the system PID settings are not within their default ranges Chiller system has no consistency Poor water flow Hot gas Bypass valve temperatures are varying Solution Exit the Autotune cycle and restart Exit the Autotune cycle and restart See Operation section entitled Autotuning Requirements Check to ensure that all water inlet and outlet valves are in the opened position See Maintenance section entitled Checking the Hot gas Bypass valve Operation Troubleshooting 6 7 Passive Alarms During a passive alarm the chiller continues to operate but if ignored could lead to a condition that will shut down the chiller NOTE Passive alarms are controlled by the Process Variable Selection Screen 27 See Operation section entitled Adjusting the Proc
83. CW 7 5 ECW 15 o ECW 3 ECW 5 ECW 10 25 5 20 5 1 7 5 15 a 10 5 0 0 5 10 15 20 25 30 35 40 45 50 55 Flow Rate GPM C 1 Appendix Water Quality Control Insufficient or improper water treatment can damage the EarthSmart Chiller A certified water treatment specialist should be consulted for your particular application It is the owner s responsibility to prevent damage from foreign material or inadequate water treatment The two main points to consider for water treatment in chillers are Corrosion Organism growth Proper chemical treatment will control pH levels and algae growth Appendix D 1 Overhead Plumbing Details Overhead piping installations above process connections require installing a check valve in the Process line and 12 inch 305 mm riser with check valve and vacuum break in the From Process line to prevent siphoning when shutting down the chiller Install a vent tube 12 inches 305 mm above the highest system point to prevent over pressurization Maximum height of piping above process connections is 25 ft 7 6 m vacuum break X internal vent 12 in 305 mm above highest water level check valve 12 in 305 mm Water outlet water cooled only Condenser Water inlet water cooled only back view To Process outl
84. Checking the Refrigerant Charge and Quality Have a certified refrigeration technician service the chiller Check air water temperature Water should be 75 F 23 8 C or higher air temperature should be 70 F 21 1 C or higher Re adjust fan cycling pressure switch setting See Appendix L entitled Pressure switch settings Troubleshooting 6 15 6 16 Shut Down Alarms continued The chiller has automatically shut down because it has detected a serious problem that could damage your material or chiller Symptom Possible cause Refrigeration Pressure Wiring incorrect Switch Low continued PSL Improperly adjusted Low Pressure Inhibit Time LP i Improperly adjusted Low Pressure Delay Time LP d To Process Temperature Damaged To Process RTD Element Failure tE1F t NOTE This alarm is only passive when the chiller is controlling from From Process From Process Damaged From Process RTD Temperature Element Failure tE2F Loose or damaged RTD connection Troubleshooting Loose or damaged RTD connection Solution Use wiring diagrams and check wiring Correct as needed Re adjust Low Pressure Inhibit Time see Operation section entitled Adjusting the Low Pressure Inhibit Time LPi Re adjust Low Pressure Delay Time see Operation section entitled Adjusting the Low Pressure Delay Time LP d Replace Process RTD See Troubleshooting section entitled R
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86. EarthSmart Portable Chillers come fully assembled in a single crate Some air cooled units are shipped without the casters attached The casters must be attached during unpacking N CAUTION Lifting EarthSmart Portable Chillers are designed to easily roll on casters If for some reason you need to lift the chiller take all precautions to avoid personal injury or damage to the chiller Lift the chiller using a forklift or hoist with straps that have been positioned at the chiller s center of gravity Do not try to lift the unit manually 1 Carefully uncrate the chiller and its components 2 Remove all packing material protective paper tape and plastic Compare contents to the shipping papers to ensure that you have all the parts 3 Carefully inspect all components to make sure no damage occurred during shipping If any damage is found notify the shipping agent immediately to file a claim Check all wire terminal connections bolts and any other electrical connections which may have come loose during shipping Check for pinched wires and kinked hoses 4 Remove the bands holding the chiller on the pallet 5 With a forklift lift the chiller high enough to attach the casters if shipped unattached Thread the casters into the threaded plates on each corner of the unit 6 Record serial numbers and specifications for the chiller in the blanks provid ed on the back of the User Guide s title page This information will be helpful if you
87. F SCREEN 107 Optional o a Z 00 OFF Function This screen tests the functionality of the fan motor Use the or buttons to test the fan The button will activate the fan and keep it on until the button is pressed This screen tests the functionality of the Liquid Line Solenoid valve LLSV The liquid line solenoid valve isolates the high and low sides of the compressor Use the or buttons to test the valve The button will open the two halves of the compressor and will leave them open until the button is pressed This screen tests the functionality of the optional audible and visual alarm indica tors Use the or buttons to test the alarm indicators The button activates the alarm indicators and will leave them on until the button is pressed NOTE Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password 9 NOTE The chiller must be in Standby mode to test outputs To access Standby mode press the Stop button on the control panel during normal operation n E 5 Qu 7 oFF This screen tests the functionality of the Autofill operation Use the or but tons to test Autofill The button will allow water to flow into the chiller s reser voir and will leave i
88. G THE TI 31AA MODULE OR ITS ATTACHED SENSOR WIRING BE AWARE THAT THE SENSOR TERMI NAL C HAS THE SAME VOLTAGE AS TERMINAL L1 Disconnect control circuit power to de energize the module Connect a jumper wire across the control circuit M1 M2 terminals on the module control circuit terminal board This will bypass the control contact of the module Reconnect control circuit power If the compressor will not operate with the jumper wire installed then the problem is external to the solid state protection System If the compressor operates with the mod ule bypassed but will not operate when the jumper wire is removed then the control circuit relay or triac in the module is open If after allowing time for motor cooling the protec tor still remains open the motor sensors may be checked as follows see Figure 8 a Disconnect control circuit power to de energize the module Remove the jumper of Step 2 Re move wiring connections from the sensor and common terminals on the module control circuit terminal board b CAUTION Use Ohmmeter with a maximum 9 VAC for checking The sensors are sensitive easily damaged and no attempt should be made to check continuity through them with other than AL Check Resistance Between Terminals C and S1 S2 or S3 Note Remove Wiring Connections to Module Before Checking Resistance Checking Resistance Through Solid State Sensors Figure 8 Appendix J 5 J
89. Glycol screen Screen 88 is displayed Actual Setpoint 5 Use the buttons to toggle between Yes or No for glycol mixture 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu lt gt Operation 4 51 ec 4 52 TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation speed Operation Adjusting the Process Variable Selection The EarthSmart Chiller s controller allows the user to select where the Actual process temperature will be read from Process From Process or Average Depending upon the specific setup of your process adjusting this parameter will provide a more accurate temperature readout To adjust the Process Variable Selection 1 Press and release both the Scroll and Function buttons together until the main screen of the Input Menu Screen 26 is displayed Actual Setpoint 2 Press the Scroll button until the Control screen Screen 27 is displayed Actual Setpoint 3 Use the or buttons to toggle between to fro or Avg selections 4 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu t NOTE Conair recommends using the To Process process variable
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92. Menu Screen 49 is displayed Actual Setpoint Press the Scroll button until the Autofill Alarm Timer screen Screen 71 is displayed Setpoint Use the or buttons to increase or decrease the amount of time delay Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Adjusting the Compressor Cycles per Hour Alarm Setpoint nCCH This setting is used to adjust the number of compressor On Off cycles per hour the chiller s control will allow before activating a shutdown alarm The one hour time frame is started when the user presses the Start button and refreshes every hour after startup The range for this setting is 2 to 15 cycles hour and the standard default setting is 10 cycles per hour ec TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation speed To adjust the Compressor Cycles per Hour Alarm Setpoint 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main Menu 3 Press and release both the Scroll and Function buttons together FUNC until the main screen of the Alarm Setup Menu Screen 49 is displayed D 5 A gt Setpoint 4 Press the Scroll
93. Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed FUNC 77 Actual m A Et Setpoint 4 Press the Scroll button until the Alarm Silence Timer screen Screen 70 e is displayed Setpoint 5 Use the buttons to increase or decrease the temperature setting 6 Press the Scroll button to lock in the selection or press the Function Ig button to lock in the selection and exit to the Main Menu Operation 4 77 ec TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation 4 78 speed Adjusting the Autofill Alarm Timer AF t optional This setting is used to adjust the amount of time after the chiller s control has not received an input signal from the optional reservoir float switch before activating an alarm The range for this setting is 0 to 900 seconds and the standard default setting is 300 seconds To adjust the Autofill Alarm Timer 1 az Operation Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password Press the Function button to save the password entry and exit to the Main Menu Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup
94. Setpoint Temperature Lower the Process Low Alarm setpoint See Operation section entitled Adjusting the Process Low Alarm setpoint LA L Adjust the Process Low Alarm Inhibit Time setpoint See Operation section entitled Adjusting the Process Low Alarm Inhibit Time Adjust the Process Low Alarm Delay Time setpoint See Operation section entitled Adjusting the Process Low Alarm Delay Time LA d Enable glycol usage see Operation section entitled Glycol Operation Enable Disable Adjust water flow to your specific chiller model See Description section entitled Specifications EarthSmart ECW and ECW Series Verify that the compressor contactor disengages in Stop mode replace as necessary Shut Down Alarms The chiller has automatically shut down because it has detected a serious problem that could damage your material or chiller Symptom Temperature Controller Loop Break Failure tCF Flow Switch Loss FSL Possible cause Hot gas bypass valve is damaged or clogged Load on the chiller is too high or low Initial process fluid temperature is either extremely too high or low Loop Break timer is set too low Improper Autotune At start up no water flow is detected The chiller s pump is not operating The chiller s pump motor starter has tripped Incorrect pump rotation Solution Have a certified refrigeration technician replace the solenoid valve Reduce or increa
95. Z co nCCH n m Ww N Function This screen displays the Process Loop Break Time This setting is used to adjust S NOTE Grey shaded the amount of time the Process Loop screens denote supervi Break will wait before alarming Screen sor functions To access 68 However if the actual temperature reaches the setpoint temperature The timer an on the delay time will reset Use the and buttons to change this setting The entitled Using the range is 0 to 900 seconds Supervisor s Password the supervisor screens This screen displays the Alarm Silence Timer This setting is used to adjust the amount of time after the Alarm Acknowledgement button has been pressed that the optional beacon and visual alarms will be de activated However if the alarm condition has not been satisfied the optional beacon and visual alarms will be re activated Use the and buttons to change this setting The range is 0 to 120 minutes This screen displays the Autofill Alarm Timer This setting is used to adjust the amount of time after the control does not receive an input signal from the chiller s reservoir float switch before signaling an alarm and shutting off Autofill Use the and buttons to change this setting The range is 0 to 900 seconds This screen displays the Compressor Cycles Per Hour Alarm Point This setting is used to adjust
96. a minimum of 20 F 7 C Capacities are 5 based on the compressor manufacturer s ratings and are subject to change with out notice Consult with a Conair representative for other conditions Capacities change depending on selected options T Standard design based on 50 F 10 C to process with 60 F 16 C return from process Standard pump pressure rating does not include internal chiller losses Specifications may change without notice Check with your Conair representative for the most current information Description 2 11 Pump curves ECW Series Water cooled 100 90 80 70 60 Pressure psi 50 40 30 20 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Flow Rate gpm SPECIFICATION NOTES Pump availability 0 75 Hp standard for 1 5 ton 1 Hp standard for 3 ton 1 5 Hp standard for 5 7 5 and 10 ton and optional for 1 5 ton 2 Hp standard for 15 ton and optional for 3 ton 3 Hp A optional for 3 5 7 5 and 10 ton 3 Hp B standard for 20 and 25 ton 5 Hp standard for 30 ton and optional for 5 and 15 ton 7 5 Hp optional for 7 5 10 20 25 and 30 ton 10 Hp optional for 15 ton 15 Hp optional for 20 25 and 30 ton Pump curves do not reflect pressure drops due to internal piping These pump curves are non overloading using the service factor of the motors Specifications may change without notice Check with your Conair representative for the mo
97. acity than the process load Location Choose a water cooled chiller when tower water or another inexpensive water source is available Choose an air cooled model for maximum portability of the unit or if an inexpensive water source is unavailable Temperature The normal temperature range of discharge chilled water is 20 F to 70 F 6 7 C to 21 1 C For applications requiring 40 F 4 4 C and lower process fluid temperatures mix an industrial grade ethylene or propylene glycol with the water to the correct percentage by volume to protect against process freezing See Installation section entitled Filling the Chiller Use this information as a general guide Consult your Conair representative for assistance when choosing a Conair EarthSmart Portable Chiller Description 2 3 How it Works EarthSmart ECW Series Water cooled Models Process circulation Hot fluid from the process enters the chiller through the 5 From Process connection am into the pump reservoir be 2 The pump draws water from e M A the pump reservoir and I moves it through the strainer p and flow switch to the evap orator Lace den 3 The process fluid is chilled right side as view from the control panel in the evaporator and exits through
98. air sales representative also n 3 Service or Parts Department for can help analyze the nature of your problem assuring that it did not result from ie nominal fee Most manuals can misapplication or improper use be downloaded free of charge from the product section of the Conair website How to Contact Customer Service www conairgroup com To contact Customer Service personnel call PA TERNATIONAL 18 amp NOTE Normal operating hours 8 00 5 00 pm EST After hours emergency service is available at the same phone number Before You Call If you do have a problem please complete the following checklist before calling Conair CJ Make sure you have all model control type and serial numbers from the serial tag and parts list numbers for your particular equipment Service personnel will need this information to assist you g Make sure power is supplied to the equipment 7 Make sure that all connectors and wires within and between control systems and related components have been installed correctly Check the troubleshooting guide of this manual for a solution Thoroughly examine the instruction manual s for associated equipment especial ly controls Each manual may have its own troubleshooting guide to help you Check that the equipment has been operated as described in this manual g Check accompanying schematic drawings for information on special consid
99. all OSHA and other safety regulations pertaining to the use of compressed air Checking the Refrigerant Charge and Quality WARNING Refrigerant hazard Only certified refrigerant technicians should examine and correct problems involving the refrigerant circuit CAUTION Always disconnect and lock out the main power sources before making electrical connections Electrical connections should be made only by a qualified electrical technician All chillers are fully charged with R 410A refrigerant from Conair Your chiller s model nameplate identifies the type and amount of total refrigerant charge required See Description section entitled Specifications EarthSmart ECW and ECA Series Check refrigerant charge while the chiller is running under normal load Check the refrigerant charge through the sight glass Use a flashlight if necessary and check the liquid line sight glass Under full load conditions the refrigerant should be clear no bubbles Under low load conditions when the Hot Gas Bypass valve HGBP is operating bubbles may be visible in the sight glass This is normal If the charge is low and the chiller is under warranty contact Conair service or have a local certified refrigeration technician add R 410A refrigerant to the system A refrigerant quality label is located within the sight glass A green label is normal A yellow or dark brown label indicates that the refrigerant is contaminated Sig
100. anching resistance in the event of high tempera tures The sensors are calibrated for proper motor protec tion Copeland will be phasing in a new supplier for solid state modules and sensors semi hermetic reciprocating compres sors The new supplier will be Kriwan Industrie Elektronic GmbH The new Kriwan modules INT369R and sensors are UL recognized and are identical in performance fit and function No wiring changes are required They also passed all tests for equivalency and reliability The change to Kriwan sensors in 4D 6D new production compressors will begin in September 2003 through the summer of 2004 The part number wholesalers purchase will not change but the mod ule part number in that kit will change as this transition oc curs All Texas instruments TI and Robertshaw will be obsolete 2004 Also any previous Robertshaw system with low resistance sensors MP13 23 and 33 has been obsoleted 1981 998 0524 10 Module Kit 071 0581 00 Kriwan Module INT369R 003 0764 00 Adaptor Plate 929 0001 01 Wire Harness The solid state modules have been developed to interpret the sensors resistance The modules Kriwan INT369B C R TI 41AA1600E 31AA1600E and TI 15AA1600B C or Robertshaw MP50 and 3450 are electrically inter changeable If replac ing one of the older style modules with a new Kriwan INT369R TI 41AA1600E or 31AA1600E adapter plate and a wiring harness is required These will be included with the new m
101. and 114 000 Btu H at 20 120 F using 60 Hz electrical power This bulletin covers the application parameters recommended for operating these compressors properly Nomenclature The ZB KC ZB KCE refrigeration scroll model number includes two digits that indicate the amount of cooling capacity in thousands of Btu H at the 60 Hz ARI rating point 20 120 F with R404A in the third and fourth location e g ZB92KC produces approximately 92 000 Btu H For actual compressor performance information please visit Emerson Climate Technologies Online Product Information at www emersonclimate com Operating Envelope The Copeland Scroll refrigeration models can be used with a variety of refrigerants Table 1 shows these selection options The operating envelopes are depicted in Figures 1A 1B 1C 1D 1E and 1F Figure 1A ZB KCE excluding ZB95KCE amp ZB114KCE Application Envelope for R404A R507 MT Applications 7 15Hp 65 F Return Gas Qa gt 2 W o N o 2 o o o N o o o Condensing Temperature 2 a 20 10 20 30 40 50 60 F Evaporating Temperature Figure 1B ZB95KCE amp ZB114KCE Application Envelope for R404A R507 MT Applications 7 15Hp F 65 F Return Gas 150 20 F SH Condensing Temperature a o 20 10 o 10 20 30 40 50 eo F Evaporating
102. below 50 F 10 C to a minimum of 20 F 7 C Capacities are 5 based on the compressor manufacturer s ratings and are subject to change with out notice Consult with a Conair representative for other conditions Capacities change depending on selected options Standard design based on 50 F 10 C to process with 60 F 16 C return from process Condenser water based on 85 F 29 C supply and 95 F 35 C return Standard pump pressure rating does not include internal chiller losses Specifications may change without notice Check with your Conair representative for the most current information 2 10 Description Specifications EarthSmart ECA 7 1011 Series Air cooled Models Performance characteristics Nominal capacity tons kW 1 5 5 3 3 0 10 5 5 0 17 6 8 0 28 1 10 4 36 5 14 1 49 5 22 6 79 4 24 8 87 1 29 4 103 3 Compressor qty Hp kW 1 15 1 12 1 3 2 24 1 5 373 1 7 5 5 59 1 10 7 46 1 15 11 19 1 20 14 91 1 25 18 64 1 30 22 37 Standard process pumpt Hp kW 0 75 0 56 1 0 0 75 1 5 1 12 1 5 1 12 1 5 1 12 2 0 1 50 3 0 2 25 3 0 2 25 5 0 3 73 Standard process flow gpm l min 4 0 15 1 8 0 30 3 13 0 49 2 20 0 75 7 26 0 98 4 35 0 132 5 56 0 212 0 61 0 230 9 73 0 276 3 Standard process pressure psi bant 33 0 2 28 38 0 2 62 43 0 2 96 40 0 2 76 39 0 2 69 38 0 2 62 29 0 2 00 28 0
103. button until the Process High Shutdown Inhibit screen Screen 58 is displayed E Actual Setpoint 5 Use the or buttons to increase or decrease the amount of time delay 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu b Operation 4 65 ec TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation 4 66 speed Operation Adjusting the Process High Temperature Shutdown Delay Time H Sd This setting ensures the chiller will begin to lower the process coolant s tempera ture during normal operation before alerting the user to a shut down alarm The range for this setting is 0 to 60 seconds and the standard default setting is 5 seconds To adjust the control s Process High Temperature Shutdown Delay Time 1 T Cc Ia Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password Press the Function button to save the password entry and exit to the Main Menu Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual Setpoint Press the Scroll button until the Process High Shutdown Delay screen Screen 59 is displayed
104. came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only Autofill board 20 Close the electrical enclosure once wiring of the Autofill option is complete G 7 Appendix continued Installing Autofill optional continued 21 Test the Autofill installation by closing the drain valve and opening the Autofill supply water 22 Check for leaks by the solenoid valve or on any other fittings and repair as needed 23 Turn on main power supply to the chiller and listen for the solenoid valve to open and monitor the level gauge until the gauge is full Appendix G 8 Cleaning the Autofill Valve optionan AX WARNING Electrical hazard Before performing any work on this unit disconnect and lock out electri cal power sources to prevent injury from unexpected energization or startup If the EarthSmart Chiller has the optional Autofill valve it may periodically need servicing to keep the free flow of incoming water into the chiller s reservoir The clean replace the optional Autofill valve 1 Disconnect and lockout power to the chiller 2 Shut of the To Process and From Process factory optional and Autofill water sources valves Autofill inlet Oi From Process mA EVA E Process lt i valve 3 Open the Fill Drain valve on the back of the chiller to drain out the process fluid To Pr
105. cate specific electrical components Illustrations in the User Guide are intended to be representative only 6 Close the electrical enclosure and apply main power to the chiller to test the installation Q NOTE Passive alarms will not activate an alarm output from the chiller s control Installation 3 17 3 18 Installation Operation Basic control 5 4 4 EarthSmart Chiller control functions 4 5 Control function flow charts 4 5 How to navigate the menu tree 4 5 EarthSmart Chiller menu tree 4 6 Control function descriptions 4 14 Before 5 4 40 Starting the chiller 4 41 Stopping the 4 42 EarthSmart Chiller sequence of operation 4 43 Adjusting setpoint temperature 4 44 How to use the supervisor s password 4 45 5 Autotuning requirements 4 46 Autotuning 4 46 Changing from fahrenheit to celsius units 4 49 Enabling Disabling display decimal point for temperature 4 50 Glycol operation enable disable 4 51 Adjusting the process variable selection 4 52 Autofill enable disable optional 4 53 Setting serial Modbus communication ID 4 54 Adjusting serial baud rate 4 55 Operation 4 1 4 2 Operation Setting alarm parameters
106. claims at no extra cost to the customer Refund the invoiced cost to the customer Credit is subject to prior notice by the customer at which time a Return Goods Authorization Number RGA will be issued by Conair s Service Department Returned equipment must be well crated and in proper operating condition including all parts Returns must be prepaid Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made Warranty Limitations Except for the Equipment Guarantee and Performance Warranty stated above Conair disclaims all other warranties with respect to the equipment express or implied arising by operation of law course of dealing usage of trade or otherwise including but not limited to the implied warranties of merchantability and fitness for a particular purpose Maintenance Log Reading Maintenance Item Compressor Amps 100 loaded Appendix B 1 Pressure Tables Evaporator and Piping Pressure Drops 35 ECA ECW 7 5 ECA ECW 10 ECA 13 30 Leek ECA ECW 5 25 ECW 15 a o d a 20 ECA ECW 1 5 o E T LM 15 5 10 P 5 A LAr 0 T 0 5 10 15 20 25 30 35 40 45 50 55 Flow Rate GPM Condenser and Piping Pressure Drops 40 35 ___ 1 5 30 E
107. condition descriptions TIP Pressing and hold ing the Scroll button while pressing the Function button will increase menu naviga tion speed NOTE The control will also flash the number of power cycles since first power up until the alarm condition has occurred Operation 4 23 TIP Pressing and hold ing the Scroll button while pressing the Function button will increase menu naviga tion speed S NOTE Grey shaded 4 24 screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Operation Control Function Descriptions Screen SCREEN 49 AL o Q 5 2 n mi Z LP d BE 2 52 FL i 10 Function This is the first screen of the Alarm Setup Menu tree To access this screen press and release both the Scroll and Function buttons until this screen is shown on the chiller s dual LED display This screen displays the Low Pressure Inhibit Time This setting is used to adjust the amount of time after chiller start up the Low Pressure Alarm input will be ignored This is used so that the chiller can generate enough coolant pressure to begin normal operation Use the and but tons to change this setting The range is 0 to 120 seconds This screen displays the Low Pressure Delay Time This setting is used to adjust the a
108. ct and lock out electrical power sources to prevent injury from unexpected energization or startup 1 Disconnect and lockout power to the chiller 2 Open the chiller s electrical enclosure continued Connecting the Main Power Source continued 3 Connect the power wires to the terminals See the wiring diagrams that came with your chiller Route the power cable through the hole in the top of the electrical enclosure and secure it with an appropriate strain relief Terminals leads Ground lug 4 Check terminal screws to ensure that the wires are secure Gently tug each AN wire if a wire is loose use an appropriately sized screwdriver to tighten the terminals IMPORTANT Always refer to the wiring diagrams that 5 came with your chiller to Connect the ground wire to the grounding lug locate specific electrical components Illustrations in 6 Close the chiller s electrical enclosure once all connections have been made the User Guide are intended to be representative only Installation 3 11 A IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only IMPORTANT Conair recom mends checking all main wiring for loose connections before putting the chiller into service 3 12 Installation Checking Electrical Connections N WARNING Electrical Hazard Befo
109. ct unplug and lockout the main power source before opening the unit for servicing 2 Remove the chiller s left side panel as viewed from the control 3 Locate the high refrigeration safety switch 4 Push the Reset button 5 Replace the chiller s left side panel as viewed from the control 6 Reapply main power A IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only Appendix M 1
110. default setting is 5 seconds ment can be harmful to the compressor s life To adjust the control s Low Pressure Delay Time span and may void warranty 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main Menu i 7 FUNC 3 Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed TIP Pressing and holding the Actual Scroll button while press ing the Function button will increase menu navigation speed Setpoint J 4 Press the Scroll button until the Low Pressure Inhibit screen Screen 51 is displayed Actual A Setpoint 5 Use the buttons to increase or decrease the amount of time delay button to lock in the selection and exit to the Main Menu 6 Press the Scroll button to lock in the selection or press the Function Operation Adjusting the Flow Switch Alarm Inhibit Time FL i This setting ensures that there is adequate flow through the evaporator before TIP Pressing and holding the allowing the compressor to start The time set at this screen is the time after initial Scroll button while press start up of the chiller that the control will wait before indicating an alarm and shut ing the Function
111. display This screen displays the Supervisor s Password This setting is used to gain access to supervisor screens within the control Use the and buttons to enter the password The supervisor pass word is 210 See Operation section enti tled Using the Supervisor s Password This screen displays the Units Selection This setting is used to change the chiller s temperature readout to either Fahrenheit or Celsius Use the and buttons to toggle between the two selections A cor responding LED on the control panel will illuminate under the current selection See Operation section entitled Changing from Fahrenheit to Celsius Units This screen displays the Decimal Display Point for Temperature This setting is used to include the decimal point reading for temperature Use the and buttons to toggle between or off See Operation section entitled Enabling Disabling Display Decimal Point for Temperature Display TIP Pressing and hold ing the Scroll button while pressing the Function button will increase menu naviga tion speed NOTE Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Operation 4 33 Q NOTE Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password 5 NOTE Etherne
112. e Alarm Log Possible cause Low water flow through the condenser Water cooled only Ambient air temperature is too high Air cooled only maximum 95 F 35 C Condenser water inlet temperature is too high Water cooled only maxi mum 85 F 29 4 C Improper TXV valve setting or operation Load too low for chiller Damaged or clogged Hot Gas Bypass valve HGBP Compressor cut out setpoint is set too low Process Deviation Low Setpoint is set too low Process Deviation Low Inhibit Time set too low Process Deviation Low Delay Time set too low Solution Check and or clean the water cooled condenser See Maintenance sections entitled Cleaning the Evaporator and Condenser Y Strainer and Cleaning the Brazed Plate Evaporator and Water cooled Condenser Verify proper airflow around the chiller Ensure there is no discharge air recircula tion Reduce condenser water inlet tempera ture Have a certified refrigeration technician replace the valve Increase the load on the chiller Have a certified refrigeration technician replace the solenoid valve Adjust the compressor cut out setpoint See Operation section entitled Control Screen Descriptions Screen 24 Increase the Process Deviation Low set point See Operation section entitled Adjusting the Process Deviation Low Alarm setpoint dE L Adjust the Process Deviation Low Inhibit Time setpoint See Operation section entitl
113. e Installation section entitled Filling the Chiller and Operation section entitled Adjusting the Process Temperature Switch Low Shutdown Setpoint Contact Conair Service Troubleshooting 6 19 Symptom Additional Alarms Software EEPROM Reset err 0297 err 1400 err 1401 El E E a err 1402 6 20 Troubleshooting 2 ge 5 s E wz E e geo 5 un E 5 2 Loaded Possible cause Reloading the chiller s default parameters Diagnostic of the Read only Memory during start up has failed Diagnostic of the Random Access Memory during start up has failed The system was programmed from a blank start or the system was erased and then re programmed Solution Restart the chiller to clear the alarm Restart the chiller Replace the chiller s control board Restart the chiller Replace the chiller s control board Restart the chiller Additional Alarms continued Symptom Possible cause Solution EEPROM Write Error The EEPROM writing function fails Restart the chiller testing to ensure a saved value or param err eter was written correctly Replace the chiller s control board 1403 Corrupt Alarm History Log The control fails to verify the contents of Restart the chiller the Alarm History Log during start up err The number of power cycles of the Restart the chiller chiller reaches 9
114. e by Scroll button while press the value set at this screen The range for this setting is 0 to 25 0 to 14 C and ing the Function button the standard default setting is 5 2 8 C will increase menu navigation speed To adjust the control s Process Deviation Low Alarm Setpoint 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main 20 Menu 3 Press and release both the Scroll and Function buttons together ee until main screen of the Alarm Setup Menu Screen 49 is displayed Actual D 5 A Setpoint 4 Press the Scroll button until the Process Deviation Low Alarm screen Screen 64 is displayed Ss Actual Setpoint 5 Use the or buttons to increase or decrease the temperature setting 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu b Operation 4 71 Adjusting the Process Deviation High Alarm Inhibit Time dE i ec Pressing and holding the This setting ensures the chiller will begin to lower the process coolant s tempera Scroll button while press ture during initial chiller start up before alerting the user with a passive alarm The ing the Function button
115. e in Tube style heat exchangers made with cop per and steel Follow rec ommended guidelines of the cleaning solution supplier for mixtures based upon the severity of fouling NOTE These connections may vary depending on the model you have purchased Be sure to see the labeling on your particular unit 5 8 Maintenance Cleaning the Brazed Plate Evaporator or Water cooled Condenser continued CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting 6 Remove RTD from bottom of evaporator or condenser 7 For the evaporator connect 1 2 inch tubing to the 1 2 inch connections of the heat exchanger SEE below to install customer supplied chemical pump and solu tion fitted to the heat exchanger 7b For the condenser remove 3 8 inch heat exchanger plug to drain Connect as shown below and back flush SEE below to install customer supplied chemical pump and solution fitted to the heat exchanger 8 Back flush the solution through the heat exchanger and the chiller 9 Flush the heat exchanger and the chiller piping with fresh water after cleaning 10 Reconnect the chiller pump to the heat exchanger Remove the cap in the heat exchanger and reconnect the hose from the pump 1 2 inch connection on
116. e temperature setting 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu e 4 Operation 4 67 Adjusting the Process Low Alarm Inhibit Time L Ai e TIP Pressing and holding the This setting ensures the chiller will begin to raise the process coolant s temperature Scroll button while press during initial chiller start up before alerting the user with a passive alarm The ing the Function button range for this setting is 0 to 180 seconds and the standard default setting is 10 will increase menu navigation Seconds speed To adjust the control s Process Low Inhibit Time 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main FUNC Menu 3 Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed E C Z O Actual Setpoint Press the Scroll button until the Process Low Alarm Inhibit screen Screen 61 is displayed iS Actual Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Setpoint 9 5 Use the or buttons to increase or decrease the amount of time delay
117. ease menu naviga F Put tion speed SCREEN 27 This screen displays the Process Control Input This screen dictates where the NOTE Grey shaded CtL chiller will read its actual temperature screens denote supervi To Process From Process or an sor functions To access Average of the two values Use the the supervisor screens to and buttons to choose between the set see Operation section tings entitled Using the Supervisor s Password n 7 m trj Z N oo This screen displays the time period the chiller s control will sample the To Es Process temperature A long time dura tion between samples will allow for tem perature jumps a low duration will help accuracy but may trigger alarms due to temperature fluctuations Use the and buttons to change this setting The range is 0 1 to 10 seconds B o 2 s 2 N This screen displays the time period the chiller s control will sample the From Process temperature A long time dura tion between samples will allow for tem perature jumps a low duration will help accuracy but may trigger alarms due to temperature fluctuations Use the and buttons to change this setting The range is 0 1 to 10 seconds p Operation 4 21 Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled U
118. ed Adjusting the Process Deviation Low Alarm Inhibit Time dE i Adjust the Process Low Delay Time setpoint See Operation section entitled Adjusting the Process Deviation Low Alarm Delay Time dE d Troubleshooting 6 11 6 12 Passive Alarms During a passive alarm the chiller continues to operate but warns of a problem that could prevent correct cooling of your process fluid If ignored this problem could lead to a condition that will shut down the chiller By NOTE Passive alarms are control by the Process Variable Selection Screen 27 See Symptom Process Temperature Switch Low tSL t NOTE This alarm automatically clears when the alarm condi tion is resolved Pressing the Alarm Acknowledgement button is not require The alarm will be present in the Alarm Log Troubleshooting Possible cause Load too low for chiller Initial process temperature is too low User entered process fluid temperature too low Process Low Alarm Setpoint is set too high Process Low Alarm Inhibit Time set too low Process Low Alarm Delay Time set too low Glycol usage not enabled Water flow is too low Faulty compressor contactor Operation section entitled Adjusting the Process Variable Selection Solution Increase the load on the chiller Increase initial process fluid tempera ture Increase user entered process tempera ture setpoint See Operation section enti tled Adjusting
119. ed Water Quality Control J Checking electrical connections amps and volts Make sure electrical connections are properly seated See Maintenance sec tion entitled Checking Electrical Connections Check fan compressor pump amps and volts by checking the data tag located inside the electrical enclosure See Description section entitled Specifications EarthSmart ECW and ECA Series 7 Cleaning Wipe all external surfaces to maintain finish C Inspecting condenser Check the condenser for adequate airflow or water flow Check the condens er surface for dirt and clogging If dirt or clogs are present clean the con denser See Maintenance sections entitled Cleaning the Evaporator or Water cooled Condenser and Cleaning the Air cooled Condenser Check clean and replace the filter at the air inlet of the air cooled condenser coil inspect and clean the fan blades as needed J Inspecting the control panel Check for loose wires burned contacts and signs of overheated wires Check that all panel lights illuminate See Maintenance section entitled Checking Electrical Connections C Checking refrigerant charge With the compressor running check the sight glass between the receiver and evaporator for proper refrigerant condition See Maintenance section entitled Checking Refrigerant Charge C Cleaning the Evaporator and Condenser strainer See Maintenance section entitled Cleaning the Evaporator and Condenser Y Strainer
120. eeded Shutdown CCPH Process Temperature Switch Low Shutdown Freeze Protection tSLL Possible cause The compressor Cut in and Cut out set points are too low The Hot gas Bypass valve is not func tioning properly The chiller has not been properly tuned Load too low for chiller Damaged or clogged Hot gas Bypass valve Glycol usage not enabled Faulty flow switch Process setpoint is set too low The compressor Cut out setpoint is improperly adjusted Solution Increase the Cut in and Cut out set points See Operation section entitled Control Function Descriptions Screens 24 and 25 Check to ensure the chiller is sized cor rectly to your application See Description section entitled Specifications EarthSmart ECW and ECW Series See Maintenance section entitled Checking the Hot gas Bypass Valve Reload factory Autotune presets See Operation section entitled Control Function Descriptions Screens 13 14 15 and 16 Increase the load on the chiller Have a certified refrigeration technician replace the solenoid valve Enable glycol usage see Operation section entitled Glycol Operation Enable Disable Check flow switch operation see Maintenance section entitled Checking or Cleaning the Flow Switch Re adjust the process setpoint higher or add glycol to the process coolant and re adjust the Process Temperature Switch Low Shutdown setpoint to allow lower temperature Se
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122. egers with scaling factors Before these values can be read or written to the control the appropriate scaling factor must be applied AII process variables are stored in degree Celsius Some special registers contain bit ori ented information such as alarms In order to read these registers correctly the Modbus master or PLC embedded controller etc should perform a bit mask to the incoming integer value to strip the information required Some critical parameter addresses are read only A Quick Block grouping that was created pertains all of the most commonly used registers if required using this block can increase network speed 2 2 N Front of Ethernet connector located on the front of the EarthSmart Chiller s electrical box Appendix K 3 I POWN XS 5 8 43 1149 uo qOL SNACGOW 39u19033 pue NLY Snadow Ieues 107 6002 82 10 0 08 08 001 0 NANO WI 802 8020 1 0 0 YO UO 1urodjes oj 1 102 20207 0 0 perdoo si enjeA Jeyy Aiowey pares 2 oor enen Wve qulodyes sseooud WIS 902 9020 yurwo 9002 002 qurqubiH 00 ene 9 sseooud
123. electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equipment A CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting The air cooled condenser can accumulate dirt and clog quickly if it is ran in a dusty or dirty environment A clogged condenser increases refrigerant discharge pressure lowers performance and may cause the fan motor s and compressor to overheat To clean the air cooled condenser 1 Disconnect and lockout power to the chiller 2 Remove the wire mesh air filter that is located on the side of the chiller by lifting up and out Air filter 3 Inspect the coils Use a flashlight to check between coil surfaces Clean the dirty coils with a soft brush or vacuum Flush with cool water or a commercial coil cleaner that is compatible with aluminum alloys Conair recommends spraying the coil cleaner from inside the chiller s cabinet 5 Inspect and clean the air filter Replace as needed A CAUTION Wear eye protection If you use compressed air to clean the equipment you must wear eye pro tection and observe
124. electrical techni cian in accordance with electrical codes in your region 1 Be sure the main power is disconnected and or the chiller s optional disconnect switch is locked out Always disconnect and lockout the main power source before opening the unit for servicing Open the electrical enclosure Inspect all wires and connections Look for loose wires burned contacts and signs of over heated wires Compare the wiring to the wiring diagrams you received with your chiller Have a qualified electrician make any necessary repairs or replacements Close the electrical enclosure door Inspect the exterior power cords Cords should not be crimped exposed or rub bing against the frame If the main power cord runs along the floor make sure it is positioned where it could not rest in pooling water or could not be ran over and cut by wheels or casters Cleaning the Brazed Plate Evaporator or Water cooled Condenser Minerals and other contaminants produce deposits scales slime or algae on heat transfer surfaces exposed to water Fouled surfaces result in decreased cooling capaci ty Implement a water treatment program to slow the fouling ZA CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller espe cially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting Wa
125. en 49 is displayed m Z oo Actual Setpoint 2i 4 Press the Scroll button until the Process High Alarm Shutdown Setpoint screen Screen 57 is displayed Actual Setpoint Use the or buttons to increase or decrease the temperature setting 5 E T 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Adjusting the Process High Temperature Shutdown Inhibit Time H Si This setting ensures the chiller will begin to lower the process coolant s tempera ee TIP Pressing and holding the ture during initial chiller start up before alerting the user to a shut down alarm Scroll button while press The range for this setting is 0 to 900 seconds and the standard default setting is ing the Function button 300 seconds will increase menu navigation speed To adjust the control s Process High Temperature Shutdown Inhibit Time 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main Menu 3 Press and release both the Scroll and Function buttons together C until the main screen of the Alarm Setup Menu Screen 49 is displayed FUNC 77 Actual of Et Setpoint 4 Press the Scroll
126. en only enough to prevent leaks do not over tighten If process lines are higher than the chiller see Appendix E entitled Overhead Plumbing Details gt NOTE The optional From Process inlet and From Process valve locations may vary depending on the model To Process outlet Air cooled model shown Installation 3 5 Making Process Plumbing Connections continued For water cooled chillers connect the water source for cooling to the condenser water inlet on the back of the chiller then connect the condenser water outlet for returning cooling water Seal all connections with Teflon or pipe dope Water cooled chiller Condenser water in Condenser water out O o O Pressure gauge From Process inlet 7 og h Process outlet Fill drain port Air cooled chillers do not require condenser water connections The condenser for these models will be cooled by an exhaust fan located on top of the chiller Air cooled chiller Exhaust fan s st Pressure gauge O o From Process inlet S To Process outlet NE Fill drain port 3 6 Installation Filling the Chiller EarthSmart Chillers are shipped without coolant The chiller is filled manually dur x NOTE If your chiller has ing installation Use water as the coolant down to 40 F 4 4 C Below 40 F the optional Auto
127. ent Before installing this product please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet You also should review manuals covering associated equipment in your system This review won t take long and it could save you valuable installation and operating time later How the Guide is Organized Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment Read and take precautions before proceeding Numbers indicate tasks or steps to be performed by the user A diamond indicates the equipment s response to an action performed by the user An open box marks items in a checklist A circle marks items in a list Indicates a tip A tip is used to provide you with a suggestion that will help you with the maintenance and the operation of this equipment Indicates a note A note is used to provide additional information about the steps you are following throughout the manual Your Responsibility as a User You must be familiar with all safety procedures concerning installation opera tion and maintenance of this equipment Responsible safety procedures include Thorough review of this User Guide paying particular attention to hazard warnings appendices and related diagrams
128. eplacing the RTD Check RTD connection resecure as necessary Replace the From Process RTD See Troubleshooting section entitled Replacing the RTD Check the RTD connection Resecure as necessary Shut Down Alarms ontinuea The chiller has automatically shut down because it has detected a serious problem that could damage your material or chiller Symptom Process Temperature Switch High Shutdown tSHH Possible cause Hot gas Bypass valve is not working properly possibly stuck open Load is too high for the chiller Process fluid is not flowing between the supply outlet and return inlet The compressor is not running Failed Process RTD Load too high for chiller Initial process temperature is too high User entered process fluid temperature is too high Refrigerant charge is too low User entered Process High Passive Alarm Setpoint H AL is set too low Process High Temperature Alarm Delay and Inhibit times are set too short Solution Have a certified refrigeration technician replace the solenoid valve Reduce load to the chiller Check for plugged pipes closed valves or failed flow switch Check to see if compressor light is lit on the control Check power to compressor and power to compressor contactor See Troubleshooting section entitled Replacing the RTD Reduce the load on the chiller Lower initial process fluid temperature Lower user entered process fluid
129. er Y Strainer continued Water cooled only AX WARNING Electrical Hazard Before performing any work on this item disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equipment ZA CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting The EarthSmart Chiller s Y strainer can accumulate dirt and clog quickly if it is ran in a poor water quality environment which will cause poor chiller performance To clean the condenser Y strainer Water cooled only 1 Disconnect and or lockout power to the chiller 2 Shut off water flow to the condenser inlet and outlet valves factory optional 3 Remove the right side panel As view from the control 4 Locate the Y strainer at the inlet of the condenser continued 5 18 Maintenance Cleaning the Evaporator and Condenser Y Strainer continuea Water cooled only 5 Locate the evaporator Y strainer at the discharge of the condenser Evaporator Y strainer 6 Remove the center plug from the cap to drai
130. erations Appendix A 1 A 2 Appendix Equipment Guarantee Conair guarantees the machinery and equipment on this order for a period as defined in the quotation from date of shipment against defects in material and workmanship under the normal use and service for which it was recommended except for parts that are typically replaced after normal usage such as filters liner plates etc Conair s guarantee is limited to replacing at our option the part or parts determined by us to be defective after examination The customer assumes the cost of transportation of the part or parts to and from the factory Performance Warranty Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifica tions provided the equipment is applied installed operated and maintained in the recommended manner as outlined in our quotation or specifications Should performance not meet warranted levels Conair at its discretion will exercise one of the following options Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication improper installation poor maintenance practices or improper operation Replace the original equipment with other Conair equipment that will meet original performance
131. ess Variable Selection Symptom Autofill Failure optional LSH NOTE An Autofill Failure Alarm LSH turns the Autofill valve off Evaporator RTD Failure tE3F 6 8 Troubleshooting Possible cause The inlet valve for the process fluid is closed Leak in the reservoir tank Damaged water inlet hose Water pressure is low Reservoir float level switch is stuck closed or has loose or damaged wiring The float level switch is improperly installed or is damaged Loose or disconnected RTD sensor on the evaporator Damaged RTD sensor near the evaporator s suction piping Solution Open the process fluid inlet valve Check and or replace reservoir tank Replace inlet hose Increase water pressure or check to ensure water inlet valve is fully opened Increase Autofill Delay Time See Operation section entitled Adjusting the Autofill Timer optional Check and or clean the float level switch See Appendix H entitled Cleaning the Autofill Valve Check the float level switch See Appendix G entitled Installing Autofill optional Check the evaporator RTD sensor tighten or reconnect as necessary Replace evaporator RTD sensor See Troubleshooting section entitled Replacing the RTD and Appendix F entitled RTD Resistance Chart Passive Alarms During a passive alarm the chiller continues to operate but if ignored could lead to a condition that will shut down the chiller
132. essure switch opens The compressor LED will flash and the compressor will shut down once The low pressure cut out limit is reached 85 PSI 5 8 bar for temperature ranges of 40 to 70 F 4 4 to 21 1 C 50 PSI 3 4 bar for temperature ranges below 40 F 4 4 C 4 4 to 18 3 C If the cut out limit is NOT reached the compressor will shut off after 30 seconds 2 Be sure to disconnect and or lockout the main power if you have stopped the chiller to perform maintenance or repair AN IMPORTANT Do not use the main power switch to stop the chiller Turning off power to the control and chiller during normal operation prevents the necessary shut down period 4 42 Operation EarthSmart Chiller Sequence of Operation Normal Running Sequence 1 The chiller is in running mode The pump and compressor are on LEDs are illuminated 2 The chiller will maintain as close to user entered setpoint temperature as possible When the temperature is above setpoint 10046 cooling capacity is in effect to cool down the process temperature to setpoint temperature 3 Process temperature will begin to lower to setpoint temperature Depending on the PID settings the Hot gas Bypass valve HGBP will cycle as the process temperature reaches the setpoint temperature The Bypass LED will be illumi nated amp Es Compressor NOTE For air cooled models amp DA Es the fan s will remain on until E pump the coolan
133. et From Process inlet E 1 Appendix RTD Resistance Chart You can use the following chart to determine if you need to replace your RTD ey Cae oe EXE Appendix F 1 G 1 N IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only Optional Autofill hardware is available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 Appendix Installing Autofill A WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should only be installed adjusted and serviced by a qualified technician who is familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by a qualified electri cal technician in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the machine data plate N WARNING Electrical hazard Before performing any work on this equipment disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup The optional Autofill function is used to maintain the proper water level in the EarthSmart Chiller
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135. ever need service or parts Warnings and Cautions WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should only be installed adjusted and serviced by a qualified technician who is familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by a qualified electrical technician in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the machine data plate CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach temperatures up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting CAUTION Ventilation hazard The unit requires a clean and well ventilated operating environment Do not place anything on top of the unit while operating Units with top exhaust fans require unrestricted outlet air flow Water cooled units require a minimum of 1 ft 30 5 cm clearance around the perimeter for serviceability Conair recommends 2 ft 60 9 cm for ease of servicing Air cooled units require a minimum of 2 ft 60 9 cm clearance around the perimeter for serviceability and proper air flow WARNING Refrigerant hazard
136. fill func 4 4 C and down to 20 F 6 7 C use an industrial grade ethylene or propylene tion the level switch will glycol and water mixture See Installation section entitled Filling the Chiller automatically fill the Percent Glycol vs Temperature Chart reservoir after power is supplied with water as To fill with water needed See Appendix G entitled Installing Attach the water supply to Fill Drain valve or the optional Autofill port Close the To Process and From Process valves factory optional Open the Fill Drain valve or water supply Autofill option and fill chiller to the recommended level of 3 4 full on the water level gauge If the chiller is overfilled the excess water spills out the vent tube DO NOT OVERFILL Close the Fill Drain valve Check the coolant level When the chiller is turned on the coolant level drops as it begins to circulate filling the connected plumbing Check the coolant level on the back of the chiller The coolant level shows on the water level gauge Make sure the coolant level is filled to the recommended 3 4 full on the water level gauge Turn off the chiller and add more coolant if needed Disconnect water hose from Fill Drain valve The optional Autofill port does not need to be disconnected unless the chiller is to be used elsewhere Autofill port optional Water level gauge From Process inlet To Process outlet Fill Drain valve Autofill optional
137. haded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Q NOTE Conair recom mends the range between the Compressor Cut in and Cut out Deviation Setpoint should be not less than 6 F 3 3 C This will elimi nate short cycling of the compressor under light loads and increases the life of the compressor 4 20 Operation CCou n n eo D 2 8 2 2 CCin A Control Function Descriptions Function This screen displays the Compressor Cut out Deviation Setpoint This is the temper ature deviation below the user entered set point that will cause the chiller s compres sor to shut off Use the or buttons to change this setting The range is 1 to 10 F 0 5 to 5 6 C This screen displays the Compressor Cut in Deviation Setpoint This is the tempera ture deviation above the user entered set point that will cause the chiller s compres sor to turn on Use the or buttons to change this setting The range is 0 to 5 F 0 to 2 8 C Control Function Descriptions Screen Function SCREEN 26 This is the first screen of the Input Menu ec TIP Pressing and hold tree To access this screen press and ing the Scroll button release both the Scroll and Function buttons until this screen is shown on the chiller s dual LED display while pressing the Function button will incr
138. he and buttons to change this setting The range is 35 to 50 F 1 7 to 10 C or if a glycol mixture is used 15 to 50 F 9 4 to 10 C Control Function Descriptions continued Screen SCREEN 61 L Ai ar e o ZA eX L Ad un Q d m tr gt ON gt Screen 64 dE L Function This screen displays the Process Low Alarm Inhibit Time This setting is used to adjust the amount of time after chiller start up the Process Low Alarm input will be ignored This is used so that the chiller can raise the temperature of the coolant above the temperature set at Screen 60 Use the and buttons to change this setting The range is 0 to 180 seconds This screen displays the Process Low Alarm Delay Time This setting is used to adjust the amount of time after the chiller has detected a Process Low Alarm that its input will be ignored This is used to elim inate nuisance alarms Use the and buttons to change this setting The range is 0 to 180 seconds This screen displays the Process Deviation High Alarm Setpoint This setting is used to activate a Process Deviation High Alarm when the chiller s process control input Screen 27 coolant temperature exceeds the user entered coolant tempera ture by the amount set at this screen This is used to alert the operator to possible temperature fluctuations that can effect end product Use the and b
139. he TI 41AA and also the TI 31AA module may be used on either 120 VAC or 208 240 VAC All other modules must have separate models for 120 VAC and 208 240 VAC Any module output device can handle pilot circuit voltages from 24 V to 240 VAC since there is no internal connection between the output de vice circuit and the line power connection The solid state module cannot be repaired in the field and if the cover is opened or the module physically damaged the warranty on the module is voided No attempt should be made to adjust or repair this mod ule and if it becomes defective it must be returned intact for warranty replacement High Potential Hi Pot Testing The solid state sensors and the electronic components in the solid state module are delicate and can be dam aged by exposure to high voltage Under no circum stances should a high potential test be made at the sensor terminals with the sensor leads connected to the solid state module Even though the power and pilot circuit leads are not connected the module can be damaged Field Trouble Shooting In the event the motor compressor is inoperable or is not operating properly the solid state control circuit may be checked as follows It the compressor nas been operating and nas tripped on the protector allow the compressor to cool for at least one hour before checking This al lows time for the motor to cool and the control cir cuit to reset WARNING BEFORE CHECKIN
140. he relay TI 31AA TI 41AA Robertshaw or Kriwan has a rating of 2 5 amps 24 VAC to 240 VAC L2 Electronic Motor Protector Contactor Holding Coil Liquid Line Solenoid Appendix J 3 J 4 Appendix Motor Protection continued Basic Motor Protection The solid state sensor protectors provide excellent pro tection against high motor temperatures resulting from locked rotor loss of charge or motor overload The com bination of low voltage sensing and time delay provide positive protection against low voltage conditions which can occur in the pilot circuit in the event of a single phase condition on a three phase circuit Field experience indi cates that under these single phase conditions the con trol voltage can fall to a level that will cause the contactor to drop out Removing the compressor from the line can allow the voltage to increase enough to again pull in the contactor setting up a cycle of contactor chatter that can destroy either the contactor or the compressor or both The low voltage protection feature removes the compressor from the line in the event of low voltage brown out conditions The module locks the com pressor off the line until the voltage rises to the cut in setting The time delay provides a two minute delay be fore restarting each time the power circuit is opened providing protection against blips in the power supply or a chatter condition in the line power circuit Service and
141. ht glass Maintenance 5 11 Checking the Compressor s Oil Level Models ECW 7 5 and higher WARNING Electrical Hazard Before performing any work on this item disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equipment A CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting During normal operation the EarthSmart compressor oil level should be between 1 8 and 1 2 full and when at rest or in Stop mode the oil level should be 1 8 to 3 4 full To check the compressor s oil level 1 Disconnect and lockout power to the chiller 2 Remove the left side panel As viewed from the control 3 Locate the compressor it is positioned in the upper compartment of the chiller s cabinet 4 Locate the compressor s sight glass The sight glass is positioned on the bottom of the compressor 5 12 Maintenance continued Checking the Compressor s Oil Level Models ECW 7 5 and higher continued Sight glass 5 Check the compressor s oil level If no oil is visible use a flashlight and lo
142. ibit time 4 68 Adjusting the process low alarm delay time 4 69 Adjusting the process deviation high alarm setpoint 4 70 Adjusting the process deviation low alarm setpoint 4 71 Adjusting the process deviation high alarm inhibit time 4 72 Adjusting the process deviation high alarm delay time 4 73 Adjusting the process deviation low shutdown alarm setpoint 4 74 Enabling Disabling process loop break 4 75 Adjusting the process loop breaker timer 4 76 Adjusting the alarm silence timer 4 77 Adjusting the autofill alarm timer 4 78 Adjusting the compressor cycles per hour alarm setpoint 4 79 Adjusting the freeze protection shutdown alarm setpoint 4 80 Table of Contents iii 5 1 Maintenance Maintenance 5 2 Warnings and cautions 5 3 Preventative maintenance schedule 5 4 Checking electrical connections 5 6 Cleaning the brazed plate evaporator or water cooled condenser 5 7 Cleaning the air cooled condenser 5 10 Checking the refrigerant charge and quality 5 11 Checking the compressor s oil level 5 12 Checking the hot gas bypass valve operation
143. ic electrical components Illustrations in the User Guide are intended to be representative only Replacement pump compo nents are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 6 24 Troubleshooting Replacing the Contactor AX WARNING Electrical hazard Before performing any work on this unit disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup To replace contactor for the pump compressor or fan 1 2 Disconnect and lockout power to the chiller Open the electrical enclosure and locate the correct contactor Refer to the wiring diagrams you received with your chiller Disconnect the wiring from the contactor Make sure you label each wire so you can correctly install the new contactor Remove the contactor by snapping it off the DIN rail mounting Press the top of contactor downward and tip the bottom towards you Snap in the new contactor on the DIN rail Reconnect the wiring close the electrical enclosure and reapply main power to the chiller Test installation by running the chiller under normal load We re Here to Help Conair has made the largest investment in customer support in the plastics indus Additional manuals and prints for try Our service experts are available to help with any problem you might have D vail installing and operating your equipment Your Con
144. icating to several different protocol standards on the same network Conair recommends that shielded industrial grade CAT 5e Ethernet cable be used for all communication links A field connectable Ethernet terminal is included with the option which connects to the panel connection to create an 65 seal A protective lantern cap is included with the Ethernet Communications option this cap should be used when no cable is inserted to help prevent contamination Default Ethernet Parameters IP Address Subnet DHCP Assigned 255 255 255 0 Ethernet Communication T 568B Standard T569B 100 Base TX Signal s Ges 3 ee Ges continued EarthSmart Chiller Ethernet Communications continued To configure the EarthSmart Chiller for your network 1 Download Lantronix DeviceInstaller from http www lantronix com 2 Follow the on screen instructions to install the program on to your PC 3 Check to ensure that the Chiller is powered on and connected to your net work Within Lantronix Devicelnstaller use the Search for New Devices button 1 Select the EarthSmart Chiller you wish to configure and then use the Assign New IP button to adjust the network parameters to match your network See the charts beginning on the next page to read write to the desired Modbus holding register address All registers are configured as integer type Process variables tem perature and setpoints are stored as int
145. iller to automatically fill its internal reservoir This switch is normally open and closes when the reservoir is filled to its capacity On filled to capac ity Off no water filling S NOTE Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password SE NOTE The chiller must 4 38 be in Standby mode to test outputs To access Standby mode press the Stop button on the control panel during normal operation Operation SCREEN 103 ou 1 oFF SCREEN 104 ou 2 OFF SCREEN 105 oFF This screen tests the functionality of the Hot Gas Bypass valve HGBP Use the or buttons to test the valve The button will open the valve and keep it open until the button is pressed This screen tests the functionality of the process water pump Use the 4 or but tons to test the pump The button will turn on the pump and keep it on until the button is pressed This screen tests the functionality of the compressor Use the or buttons to test the compressor The button will activate the compressor and keep it on until the button is pressed AN WARNING Only qualified techni cians with proper training should test this function No alarm condi tions or guaranteed off timer Control Function Descriptions continued Screen SCREEN 106 Air cooled Only ou 4 oF
146. ing on the EarthSmart Chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting N WARNING Refrigerant Hazard Only a certified refrigerant technicians should examine and correct problems involving the refrigerant circuit Maintenance 5 3 To maintain the best perform ance follow the maintenance schedule and record informa tion in the Maintenance Log in Appendix B 5 4 Maintenance Preventative Maintenance Schedule Daily or as often as needed g Checking process fluid level in the pump tank Check the process fluid level in the water level gauge on the back of the chiller If low see Installation section entitled Filling the Chiller Verifying pump discharge pressure While the pump is running check that the pump pressure gauges not included are within range To change the pressure open or close the To Process valve Inspecting piping for leaks Check to see that pipes are not leaking Look for standing water on the floor or inside the chiller cabinet tighten and or clean as necessary Inspecting the condenser coil for debris Air cooled only Remove the wire mesh side panel and filter in front of the condenser coil Remove any debris from the coils and clean the fan blades See Maintenance section entitled Cleaning the Air cooled Condenser IMPORTANT Conai
147. ion speed FUNC b Operation Adjusting the Process Deviation High Alarm Setpoint dE H This setting is used to activate a Process Deviation High Passive Alarm when the chiller s actual process temperature exceeds the user entered temperature by the value set at this screen The range for this setting is 0 to 25 0 to 14 C and the standard default setting is 5 F 2 8 C To adjust the control s Process Deviation High Alarm Setpoint 1 2 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password Press the Function button to save the password entry and exit to the Main Menu Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual Setpoint Press the Scroll button until the Process Deviation High Alarm screen Screen 63 is displayed Actual Setpoint Use the or buttons to increase or decrease the temperature setting Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Adjusting the Process Deviation Low Alarm Setpoint dE L This setting is used to activate a Process Deviation High Passive Alarm when the e TIP Pressing and holding the chiller s actual process temperature drops below the user entered temperatur
148. ion Shutdown Alarm Setpoint screen Screen 73 is displayed Setpoint Use the or buttons to turn increase or decrease the temperature set ting Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Maintenance Maintenance Warnings and cautions 2 2 n n Preventative maintenance schedule Checking electrical connections Cleaning the brazed plate evaporator or water cooled condenser Cleaning the air cooled condenser Checking the refrigerant charge and quality sec ewe xd EE Checking the compressor s oil level Checking the hot gas bypass valve Cleaning the evaporator and condenser Y Checking or cleaning the flow switch Checking reservoir level Checking pump performance Reloading factory default parameters SECTION Maintenance 5 1 5 D 5 S 5 2 Maintenance Maintenance Features Conair EarthSmart Series Chillers need regular scheduled maintenance for peak performance To maintain the best performance of the chiller it must be cleaned and inspected regularly Maintenance includes a daily monthly and semi annual schedule See Maintenance section entitled Preventative Maintenance Schedule and
149. ion with a de gree of safety The protector cut in and cut out points will be reduced by approximately 7 F to 10 F but un der normal operating conditions this should present no problem Note At no time should more than one motor sensor be bypassed The specifications for the emergency resistor are as follows One watt or larger 2200 ohm 10 resistor EarthSmart Chiller Serial Modbus Communications The EarthSmart Chiller has the capability of communicating on a plant wide Modbus communication network Conair recommends that single twisted pair cable of at least 24 AWG with a ground sheath and sink cable should be used for all Modbus commu nications The EarthSmart Chiller has an isolated ground connection to the Modbus communication card it is advised that the ground wire be terminated on both the Modbus master and slave side With true ground local to the master The DB 9 terminal connection should match the following table EIA RS 485 Parameters mm v wem wil 1 EIA RS 485 Communications Connections DES Connection Pin GND Sheath See the charts beginning on the next page to read write to the desired Modbus holding register address All registers are configured as integer type Process variables tem perature and setpoints are stored as integers with scaling factors Before these values can be read or written to the control the appropriate scaling factor must be applied All process variables are stored
150. is enough clearance to remove all access panels completely O Available water source water cooled only If installing a water cooled unit ensure that the water source is plumbed to the chiller s installation location High points in the plumbing require vent valves low points require drain valves O Available water source for Autofill optional If installing a chiller with the optional Autofill function ensure that the water source is plumbed to the chiller s installation location See Installation section entitled Filling the Chiller Making Process Plumbing Connections Warm fluid from the process equipment enters the chiller at the From Process connection and chilled fluid returns to the process equipment through the Process connection 1 Remove the shipping plastic pipe plugs from the female connections on the back of the EarthSmart Chiller 2 Make sure the connecting process tubing male pipe threads are clean and new 3 Wrap the male pipe threads with Teflon tape or pipe dope 4 Connect the From Process valve factory option on the back of the chiller to the From Process tubing Start by hand until the threads engage and then tighten with a pipe wrench Tighten only enough to prevent leaks do not over tighten 5 Connect the To Process valve factory option on the back of the chiller to the 70 Process tubing Start by hand until the threads engage and then tighten with a pipe wrench Tight
151. k of the electrical enclosure in the upper portion of the chiller s cabinet Solenoid plug Autofill receptical 15 Locate the second port orientated on the reservoir s upper portion facing towards the front of the chiller IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only continued G 5 Appendix Installing Autofill optional continued 16 Install the Autofill switch into the port located on the reservoir s upper portion facing towards the front of the chiller using Teflon tape or pipe dope Do not over tighten Ensure that the switch is oriented vertically to allow free movement of the switch NOTE Mark the loca tion the the arrow on v the Autofill switch o This arrow must point A 4 upward for the switch to operate properly 17 Connect the Autofill switch to the Autofill 12PL receptical The Autofill switch plug is coiled near the lower back of the electrical enclosure in the upper portion of the chiller s cabinet Autofill switch receptical continued Appendix G 6 Installing Autofill optional continued AX 18 Open the electrical enclosure and install the Autofill option board into CARD1 HEADER located at the bottom right of the control IMPORTANT Always refer main board to the wiring diagrams that
152. l s Process Deviation Low Shutdown Alarm Setpoint 4 Enter the Supervisor s password within Setup Menu Branch See Operation section entitled Using Supervisor s Password Press the Function button to save the password entry and exit to the Main Menu Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual Setpoint Press the Scroll button until the Process Deviation Low Shutdown Alarm Setpoint screen Screen 67 is displayed Actual Setpoint Use the or buttons to increase or decrease the temperature setting Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Enabling Disabling Process Loop Break Lb E This setting when enabled is used to activate a Process Loop Break Shut Down Pressing and holding the Alarm when the actual process temperature is slightly higher or lower than the Scroll button while press actual user entered temperature however the actual temperature never exceeds the ing the Function button Process Deviation High or Low setpoints will increase menu navigation speed To enable the Process Loop Break 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function
153. l run with the control circuit bypassed but will not run when con nected properly the solid state module is defec tive and must be replaced The replacement mod ule must be the same voltage and be compatible with the original module on the compressor Emergency Bypass of a Damaged Solid State Sensor In the unlikely event that ONE sensor may be dam aged and have an open or shorted circuit the control module will prevent compressor operation even though the motor may be in perfect condition If such a situa tion should be encountered in the field an emergency means of operating the compressor can be used until such time as a replacement can be made Discon nect the lead from the solid state module and the faulty module control circuit terminal board sensor connec tion S1 S2 or S3 Connect a properly sized resistor between the solid state module lead and the common sensor terminal in the compressor terminal box This indicates to the control module an acceptable resis tance in the damaged sensor circuit and compressor operation can be restored see Figure 9 If an inter nal sensor is shorted the wire from the sensor to the sensor terminal should be disconnected when install ing the resistor In effect the compressor will con tinue operation with two leg protection rather than three leg protection While this obviously does not provide the same high degree of protection it does provide a means of continuing compressor operat
154. ll wiring disconnects and fuses should be installed by a qualified electrical technician in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the the machine serial tag and data plate The EarthSmart Chiller is available with optional alarm indicators a beacon and strobe light to alert the user to alarm conditions Installation of the optional alarm indicators is required only if they have not been installed from Conair To install the optional alarm beacon and strobe light 1 Disconnect and lockout power to the chiller 2 Remove the visual and audible alarms from their packaging See the wiring diagrams that came with the alarms 3 Remove the circular knockouts located at the lower left corner of the electri cal enclosure door Circular knock outs 2 4 Install the visual alarm in the top knockout and the audible alarm in the bottom knockout See the diagrams that came with the alarms continued Installing Alarm Indicators continued 5 Connect the alarms to a 24VDC power source from the termination strip in the AX electrical enclosure See the wiring diagrams that came with the alarms Secure all wiring so that the wiring terminations are not under tension when the IMPORTANT Always reter to the wiring diagrams that electrical enclosure is opened all the way came with your chiller to lo
155. lve LLSV Use the and buttons to reset the liquid line solenoid valve cycle count This screen displays the Load Default This setting is used to load all default set tings within the Setup Menu Branch except run times PID values cycle coun ters controller option type chiller type Autofill option and Hot gas Bypass valve present Use the and buttons to reset the load defaults See Maintenance section entitled Reloading Factory Default Parameters Control Function Descriptions Screen SCREEN 97 n 2 5 e pou r e OFF in 2 BE b e c in 3 nw nw e s es z 5 2 2 2 D e a oFF o 5 Ec See o B LE Function This is the first screen of the Test Menu tree To access this screen press and release both the Scroll and Function buttons until this screen is shown on the chiller s dual LED display This screen displays the status of the Flow Switch This switch is normally open and closes when water is flowing On water flow Off no water flow This screen displays the status of the High Refrigerant Pressure Switch This switch is normally closed and opens when high pressure 550 PSI 37 9 bar is reached from the compressor during a High Pressure Alarm On no high pressure Off high pre
156. mount of time after the chiller has detected a Low Pressure Alarm that its input will be ignored This is used to pre vent nuisance alarms during Hot gas Bypass valve cycling Use the and buttons to change this setting The range is 0 to 30 seconds This screen displays the Flow Switch Alarm Inhibit Time This setting is used to adjust the amount of time after chiller start up the Flow Switch Alarm input will be ignored This is used so that the chiller can begin to flow coolant Use the and buttons to change this setting The range is 0 to 60 seconds Control Function Descriptions continued Screen SCREEN 53 FL d BE n a tri 2 ER H AL co tri 2 H Ai BE o wn tr ZA H Ad Bp Function This screen displays the Flow Switch Alarm Delay Time This setting is used to adjust the amount of time after the chiller NOTE Grey shaded Screens denote supervi has detected a Flow Switch Alarm that the sor functions To access input will be ignored Use the and the supervisor screens buttons to change this setting The range is see Operation section 0 to 30 seconds entitled Using the Supervisor s Password This screen displays the Process High Alarm setpoint This setting is used to activate a Process High Alarm when the chiller s process control input Screen 27 coolant temperature exceeds the
157. mply connect the power source process piping and fill with water or with a mixture of water and industrial grade ethylene glycol or propylene glycol not automotive antifreeze Then set the process temperature These chillers are ideal for machine side cooling to maintain process tempera tures in an injection molding machine extruder or wherever you need a small moveable cooling unit Nominal capacities range from 1 4 to 29 7 tons for the water cooled models and 1 2 to 28 8 tons for the air cooled models Capacities are based on standard pump sizes and delivering 50 F 10 C coolant Operation of these units differ only in the medium used to remove heat from the refrigerant in the condensers Water cooled models are rated to use 85 F 29 C or lower cooling water from a tower well or city service air cooled models are rated to use ambient air up to 95 F 35 C Typical Applications The Conair EarthSmart Portable Chiller can be used anywhere a reliable source of process cooling water with stable temperature control is required Portable chillers are available for Injection molding Blow molding Thermoforming Extrusion Air compressors Metal plating Anodizing Laser Degreasing Heatset web offset printing presses Dryer intercoolers aftercoolers Limitations EarthSmart Portable Chillers should be chosen based upon Cooling load Select a chiller that has 0 10 more cap
158. n EarthSmart Chiller SX Actual Compressor Bypass Pump NOTE Pressing the Function button within a menu tree will also save any changes and return you to the Main Menu ec TIP Pressing and holding the Scroll button while pressing the Function button will increase menu navigation speed Operation 4 5 5 4 6 Operation EarthSmart Chiller Menu Tree Oo A POWER ON 888 888 n dui MAIN SCREEN LOOP i EarthSmart Chiller Menu Tree continued S NOTE Grey shaded screens denote supervisor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 PROCESS SETUP MENU BRANCH Operation 4 7 EarthSmart Chiller Menu Tree continued ANALOG INPUT SETUP MENU BRANCH 26 27 28 0 29 02 e 31 Coo 32 Coo Coo amp NOTE Grey shaded screens denote supervisor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password 4 8 Operation EarthSmart Chiller Menu Tree continued 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 ALARM HISTORY tSL uU UU UU E M d HH MM MENU BRANCH Operation 4 9
159. n any water in the strainer by using an appropriately sized pipe wrench 7 Remove the strainer from the strainer housing 8 Inspect the strainer Check for holes tears or filter blinding clean or replace as necessary Replacement Y strainers are 5 ilable f ir 9 Re install the strainer and strainer cap Properly seal all piping with approved Teflon tape or pipe dope Contact Conair Parts 800 458 1960 IMPORTANT Check to ensure the strainer is properly seated before applying the strainer From outside of the cap Crushing of the strainer can occur if it is not fully inserted back into the strainer United States call housing 814 437 6861 10 Check to ensure no leaking has occurred before returning the chiller to normal operation Maintenance 5 19 Checking or Cleaning the Flow Switch N WARNING Electrical Hazard Before performing any work on this item disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equipment ZA CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting
160. n is not recommended 5 22 Maintenance Checking Pump Performance CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting Checking your EarthSmart Chiller s pump performance ensures that the motor pump is operating properly Proper operation of the motor pump maintains correct water pressure to your process which allows cooling of your system To check motor pump performance 1 Check the difference between the pump discharge pressure at the Process connection inline pressure gauge not included and the pressure at the inlet of the evaporator 2 Plot the discharge pressure from the Process connection on the pump curve that is specific to your model chiller see Description section entitled Pump Curves The pump curves will indicate the flow of the process fluid in gallons per minute 3 Check the pump motor s full load amp usage Typically the pump motor will be running at 80 or higher of its full load amp FLA rating If the pump s FLA rating is below 80 there may be low process fluid flow See Installation section entitled Checking Pump Rotation 4 Check pump impeller performance if the pump motor s rotation is correct by shutting off the Process valve factory o
161. n of the Process Setup Menu tree To access this screen press and release both the Scroll and Function buttons until this screen is shown on the chiller s dual LED display This screen displays the status of the pump control MN Manual Mode and AUTO Automatic Mode Manual Mode is only selectable from initial start up or Standby Mode by pressing the Start button for 7 seconds The chiller s com pressor is deactivated in Manual Mode This screen is the Autotune On Off Pressing the button on this screen will turn on Autotune pressing the will turn off Autotune The chiller will only start an Autotune when the chiller is running and has a stable load See Operation section entitled Autotuning Requirements and Autotuning Procedure Shows the On time versus ratio of the Hot Gas Bypass valve during a cooling cycle See Operation section enti tled Control Function Descriptions Screen 17 Control Function Descriptions continued Screen SCREEN 13 26 0 SCREEN 14 int 15 0 u 3l tj 2 nr dEr n y C CYC 10 Function This screen displays the Process Proportional Gain This value is defined by the Autotune cycle A higher Proportional Gain setting will cause a faster coolant temperature change but will use more energy A lower setting will cause a slower coolant temperature change but requires less energy Once this screen
162. n severe personal injury and erratic machine operation Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non standard operating procedures such as routine maintenance Only qualified personnel should perform troubleshooting procedures that require access to the electrical enclosure while power is on continued ATTENTION Read this so no one gets hurt continued A CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the EarthSmart Portable Chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting N CAUTION Ventilation hazard The unit requires a clean and well ventilated operating environment Do not place anything on top of the unit while operating Units with top exhaust fans require unrestricted outlet air flow Water cooled units require a minimum of 1 ft 30 5 cm clearance around the perimeter for serviceability Conair recommends 2 ft 60 9 cm for ease of servicing Air cooled units require a minimum of 2 ft 60 9 cm clearance around the perimeter for serviceability and proper air flow N WARNING Refrigerant hazard Only certified refrigerant technicians should examine and correct prob lems involving the refrigerant circuit Introduction 1 5 1 6 Introduction Ho
163. ocess 4 Disconnect the Autofill water feed from the optional Autofill inlet continued H 1 Appendix Cleaning the Autofill Valve ptionan continued 5 Remove the chiller s left and right side panels 6 Locate the optional Autofill solenoid above the chiller s reservoir Autofill solenoid 7 Disconnect the solenoid plug from the Autofill 13PL receptical Solenoid plug Autofill receptical continued Appendix H 2 Cleaning the Autofill Valve optionan continued 8 Unscrew the Autofill bulkhead left handed retaining nut located on the back of the chiller Remove the bulkhead assembly from the chiller panel 9 Unscrew the bulkhead assembly from the brass fitting on the Autofill solenoid Bulkhead Brass fitting continued H 3 Appendix Cleaning the Autofill Valve continued 10 Loosen the pipe clamp on the hosing routed to the chiller s reservoir Remove hosing from the Autofill solenoid and then remove the entire Autofill solenoid from the chiller 11 Remove the four 4 bolts that hold together the top and bottom portions of the solenoid valve and open the valve Bolts 4 continued Appendix H 4 Cleaning the Autofill Valve continued 12 Inspect the top and bottom portions of the solenoid for deposit build up wear or tearing clean or replace as necessary NOTE In the image to the right the h
164. odule kit 2 20002004054 LAESA Re Motor INT369R Figure 1 120 208 240 VAC 208 240 VAC 120 VAC Connection Connection Connection RE L2 LO CONTROL T T CIRCUIT SUPPLY mac AMISSO 208 240VAC 120 JUMPER L2 TO LO SHOCK HAZAI L POWER SERVICINGIERMINAL TC THE SAME VOLTAGE AS TERMINAL 11 Me Li 12 CONTROL SUPPLY ARGUIT VOLTAGE MAC 50 80 Hz 115 120 230 240 10 46 36 i Das Ee L x0 N Electrons Motor Protector _5 AA GOOE mam 999 at e CE UN UN ME Em E el e nlii 41AA Wiring Connections For Module Figure 2 31AA Wiring Connections For Module 31AA Wiring Connections For Module Figure 3 Figure 4 This document is provided courtesy of Emerson Climate Technologies This document may be updated regularly Go to www EmersonClimate com to check for the most recent materials J 2 Appendix Motor Protection continued To Compressor Contactor Electronic Contro Module Circuit Power 4 M1 2 TI T2 Control Line Robertshaw MP 50 T 15AA Kriwan INT 369 Common Sensors C 1 S2 S3 Wiring Connections For Module Figure 5 Supply Voltage The Kriiwan INT369R and the 41AA will accept either 120 208 2
165. ok for bubbles rising in the sight glass This may be an indication of liquid refrigerant in the compressor or the compressor is overfilled with oil 6 Contact Conair Service or a certified refrigerant technician if the compressor oil level is below the recommended limits or if bubbles are visible in the sight glass 7 Replace the right side panel 8 Reapply main power to the chiller IMPORTANT Attempting to service the compressor will void any warranty Maintenance 5 13 Checking the Hot gas Bypass Valve Operation WARNING Electrical Hazard Before performing any work on this item disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equipment A CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting AN The Hot gas Bypass valve HGBP is used as a heating element to maintain the user entered setpoint temperature of the EarthSmart Chiller s process fluid The HGBP valve allows refrigerant to bypass the chiller s condenser where heat is removed Refrigerant is introduced to the evaporator to heat
166. ompressor Contactor Control Circuit 2 5A Max 600VA When the proper voltage is present and the motor temperature is within limits the M1 M2 circuit is closed and the pilot circuit is energized after the two minute off cycle time delay If the motor tem perature rises beyond safe limits the resistance of the motor sensors rises causing the control circuit to open INT369R 071 0581 00 Line Voltage 120 10 20 50 60 HZ 208 240 10 15 50 60 HZ Low Voltage Trip Low Voltage Reset Low Voltage Responds Trip Resistance Reset Resistance Resistance responds Trip Time Temperature Range Relay Contact Rating 85 VAC 5 5 VAC lt 94 5 VAC 20 15 secs 13k 3k ohms 3 25k 5k 3 2 Secs 120s 20s 40 F to 158 F 2 5 amps 600VA 170 VAC 10 VAC lt 184 VAC Same Same Same Same Same Same Same Motor Protection continued L1 L2 Module Supply Line Voltage 120 208 240 VAC These are to be connected to a power source of the proper voltage normally the line terminals on the com pressor motor contactor or the control circuit transformer as required The power requirement is very low approxi mately 6 VA 1 S2 S3 Motor Sensor Connections C Common Lead Motor Sensors Control Specification for T I Sensors Using the 41AA 31AA 15AA or the Mp50 Before 2004 1 The resistance of the sensor will vary from 500 ohms cold to 20 000 ohms hot Reset values after a pro
167. on Chiller Problems Symptom The compressor LED on the control panel is lit but the compressor is not running The Hot gas Bypass valve HGBP LED is lit but the valve is not energized Possible cause The compressor s overload has been tripped The compressor contactor is damaged or defective The compressor module is defective or damaged EarthSmart Chillers Models 15 tons and above Internal compressor motor protector has tripped EarthSmart Chillers Models 10 tons and below Loose wiring connections to the HGBP valve Damaged or defective HGBP valve coil Solution Reset and properly adjust the compressor overload Replace the contactor See Troubleshooting section entitled Replacing the Contactor See Appendix I entitled Compressor Module Troubleshooting Recycle the power and allow the chiller to sit idle for up to one hour Check interconnecting wiring resecure as necessary See Maintenance section entitled Checking the Hot gas Bypass Valve Operation Troubleshooting 6 5 tune 2 tune err3 tune err5 N lt Bp PP PP 6 6 Troubleshooting Autotuning Errors Possible cause The Hot Gas Bypass valve HGBP is not affecting the process fluid Damaged Hot gas Bypass valve coil or clogged valve The temperature deviation between the user entered temperature setpoint and the actual process temperature is less than 20 F 11 1
168. on entitled Autotune Errors for diagnoses of error codes during Autotuning Autotuning Procedure Autotuning enhances the EarthSmart Chiller control s ability to govern actual process temperature in relation to setpoint temperature Preloaded parameters are used to adjust the chiller s operation to obtain optimum functionality It is advised to perform an Autotune only under normal operating conditions and specifications To perform an Autotune 1 Adjust the Process Variable Selection Select the Process Variable the control will use for Autotuning to optimize performance See Operation section enti tled Adjusting the Process Variable Selection 2 Adjust the AutoTune PID cycle time setting Press and release both the Scroll and Function buttons together until the main screen of the Process Menu Screen 9 is displayed Autotuning Procedure continued 3 Press the Scroll button until the Cycle screen Screen 16 is displayed KA Actual Setpoint 4 Use the or buttons to increase or decrease the amount of cycle time The PID settings will cycle within the time set at this screen A short time set ting will improve how closely the chiller will maintain temperature but it will reduce the life expectancy of the HGBP valve A longer time setting will not control the chiller s temperature closely but will extend the life expectancy of the HGBP valve Standard default setting is 10 seconds 5 Press the
169. on pressure drops and the discharge pressure rises when the compressor is energized Additionally if operated in reverse the compressor is noisier and its current draw is substantially reduced compared to tabulated values TABLE 8 Connection Connection ee Stub Appendix 1 8 1 9 Appendix Compressor Module Troubleshooting continued No time delay is required on three phase models to prevent reverse rotation due to brief power interruptions Deep Vacuum Operation WARNING Do not run a Copeland Scroll refrigeration compressor in a deep vacuum Failure to heed this advice can result in arcing of the Fusite pins and permanent damage to the compressor Alow pressure control is required for protection against deep vacuum operation See Pressure Control section for proper set points Scroll compressors as with any refrigerant compressor should never be used to evacuate a refrigeration or air conditioning system See Application Engineering Bulleting AE 24 1105 for proper system evacuation procedures Unbrazing System Components If the refrigerant charge is removed from a scroll unit by bleeding the high side only it is sometimes possible for the scrolls to seal preventing pressure equalization through the compressor This may leave the low side shell and suction line tubing pressurized If a brazing torch is then applied to the low side the pressurized refrigerant and oil mixture could ignite as it escapes
170. onnec tion from the chiller s evaporator Use the and buttons to change this setting The range is 1000 to 1000 F 555 6 to 555 6 C Control Function Descriptions Screen SCREEN 34 gt o 2 ZA uo 5 a E j Ss tCF o 5 22 tSLL o 2 D e Z zj ds oo w i e o Function This is the first screen of the Alarm History Menu tree To access this screen press and release both the Scroll and Function buttons until this screen is shown on the chiller s dual LED display This is a sample of an alarm screen During an alarm condition the alpha numeric alarm code will be shown in the chiller s upper Actual display The time the alarm occurred will be shown in the lower Setpoint display See Troubleshooting section for alarm condition descriptions This is another sample of an alarm screen During an alarm condition the alpha numeric alarm code will be shown in the chiller s upper Actual display The time the alarm occurred will be shown in the lower Setpoint display See Troubleshooting section for alarm condition descriptions The chiller s control will record and store up to 40 alarms with time stamping Once 40 alarms have been accumulated the alarms will be stored in a first in first out basis See Troubleshooting section for alarm
171. onnected to the protector module terminals 51 and 52 When any thermister reaches a limiting value the module interrupts the control circuit and shuts off the compressor After the thermister has cooled sufficiently the resistance will decrease thus allowing the module to reset However the module has a 30 minute time delay before reset after a thermister trip For all other compressors conventional internal line break motor protection is provided Programmable Logic Controller Requirements If the INT69SCY 071 0620 00 or INT69SU 071 0641 00 module is applied in conjunction with a Programmable Logic Controller it is important that a minimum load is carried through the M1 M2 control circuit contacts The minimum required current through the module relay contacts needs to be greater than 100 milliamps but not to exceed 5 amps If this minimum current is not maintained this has a detrimental effect upon the long term contact resistance of the relay and may result in false compressor trips Suction Pressure Switch Switch pM i 51 52 Figure 3 Scroll Wiring Schematic L2 Compressor OMB Oil Reference Table 4 Level Control Discharge Line ea Thermostat id eed To 24VAC Supply PLC operated control circuits may not always provide this minimum current In these cases modifications to the PLC control circuit are required Consult your application engineering department for detail
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173. orking The control is not lit and there is no alarm condition The compressor hums but does not run 6 4 Troubleshooting Chiller Problems Look here if the control panel is not lit or if the power is on and the EarthSmart Chiller will not run Possible cause Power is not reaching the chiller Interconnecting control ribbon cable is loose or disconnected The correct power is not reaching the unit There is a problem with the control panel The input voltage is incorrect There is a phase loss and or the com pressor s contactor is welded shut Solution Check the power cord and plug Make sure the cord and plug are properly connected Ensure that the optional disconnect switch is in the position Check fuses breakers and power supplies Replace or reset as necessary Resecure control cable ensure the main board s LED is flashing Check the voltage specification on the chiller nameplate See Description sec tion entitled Specifications EarthSmart ECW and ECA Series The control panel may have failed Contact Conair Service Check the main supply voltage It must be within 10 of the nameplate rating Check the phase to phase voltages Check the phase continuity through the compressor contactor Check the wiring at the compressor Replace or repair as needed The motor starter protector is damaged Replace the motor starter see Appendix J entitled Motor Protecti
174. ose barb and brass fitting have been removed This is not necessary for maintenance purposes O ring seal 13 Check the resistance across each terminal of the solenoid valve with an Replacement solenoid valves ohm meter If there is infinite resistance between the terminals the or solenoid valve repair kits solenoid valve will not energize and must be repaired or replaced are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 continued H 5 Appendix Cleaning the Autofill Valve continued Remove red cap and push solenoid down Then pry here to lift nameplate retainer and push to remove Indicates Parts Supplied In Rebuild Kits solenoid base sub assembly bonnet screw 4 core assembly core spring solenoid base gasket valve bonnet diaphragm assembly bleed hole see note body gasket valve body 14 Follow steps 1 11 in reverse order to re install the Autofill solenoid Ensure to replace and properly seat the o ring seal between the top and bottom portions of the solenoid valve assembly Appendix H 6 Compressor Module Troubleshooting Introduction The Copeland Scroll ZB KC ZB KCE refrigeration compressor product offering has expanded to include higher horsepower models These new models include 7 15 Hp and produce between 50 000 Btu H
175. p button to turn off the pump and to exit Manual Pump mode Terminals leads AN If pump rotation is reversed the pump motor is turning in the wrong direction Turn off and lock out the main power source Open the electrical enclosure and reverse any two leads connecting the main power supply to the chiller 2 Check for proper pump rotation Compare the pump rotation from the motor end to the arrow direction indicator on the pump Always clockwise 3 Disconnect main power to the chiller if the pump is not rotating in the proper direction swap any two incoming power wires reapply main power 4 Press the Stop button after correct rotation has been established Check for leaks in the process piping both internal and external fix any leaks and dry the inside of the chiller before proceeding metalation 1858 nstallation A IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only amp NOTE If correct pump 3 14 rotation was established the compressor rotation will be correct Both the pump and compressor are phased together during manufacturing Installation Checking the Scroll Compressor A WARNING All wiring disconnects and fuses should be installed by a qualified electrical technician in accordance with electrical codes in your region Always maintain a safe ground
176. pendix K entitled EarthSmart Chiller Modbus Communications Ke 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu 7 Restart the chiller for the changes to take effect Adjusting Serial Baud Rate The EarthSmart Chiller s controller allows the user to select the Baud Rate of their TIP Pressing and holding the particular communications network The selections are 2400 4800 9600 and Scroll button while press 19200 ing the Function button will increase menu navigation To adjust the Baud Rate selection speed 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password FUNC 2 Press the Function button to save the password entry and exit to the Main Func Menu 3 Press and release both the Scroll and Function buttons together FUNG until the main screen of the Setup Menu Screen 83 is displayed Actual Setpoint 4 Press the Scroll button until the Baud Rate screen Screen 90 is displayed Actual Setpoint network 2400 4800 9600 and 19200 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu 5 Use the or buttons to select the Baud Rate of your communications 7 Restart the chiller for the changes to take effec
177. piping with proper flow direction Contact Conair Parts 9 Re install electrical hardware to the switch and fill the reservoir and open the 800 458 1960 To Process and From Process valves factory optional From outside of the United States call 10 Reapply main power to the chiller to test the switch 814 43r6801 Maintenance 5 21 Checking Reservoir Level AX WARNING Electrical Hazard Before performing any work on this item disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equipment Check the fluid level in the reservoir The read out in the sight glass on the back of the chiller should be 3 4 full To manually fill the reservoir 1 Disconnect and or lockout power to the chiller 2 Locate the Fill Drain valve on the back of the chiller and open the valve 3 Refill the reservoir Monitor the level using the water level indicator on the back of the chiller Because the EarthSmart Chiller can use either pure water or a glycol water mixture make sure you are adding the correct fluid for your application See Installation section entitled Filling the Chiller Autofill port Water level indicator Fill Drain valve IMPORTANT When using a glycol mixture the use of the optional Autofill functio
178. pressure control set no higher than 445 psig must be used in all applications reference Table 4 Motor Protection The larger horsepower refrigeration scroll compressors have either line break protection or the use of sensors with an electronic module The type of protection is obtained from the protector code in the model number Table 5 lists the various models protector number and the type of protection For the INT69SCY there are five PTC positive temperature coefficient internal thermisters connected in series that react with avalanche resistance in the event of high temperatures Four of the thermisters are TABLE 5 MOTOR PROTECTION Models with Line Break Protection ZB50 ZB58 ZB66 ZB76 ZB88 ZB95 ZB114 note electric code TF Models with Electronic Module ZB56 ZB68 ZB75 ZB92 ZB11M note electric code TW Models with Electronic Module 2895 28114 note electric code TW p n 071 0620 00 Model INT69SCY p n 071 0641 00 Model INT69SU Appendix l 4 1 5 Appendix Compressor Module Troubleshooting continued L1 Motor Overload Protector Discharge Pressure Motor Overload Sensors used to sense motor temperatures and the fifth is used as a discharge temperature sensor For the INT69SU there are four PTC positive temperature coefficient internal thermisters connected in series All four are used to sense motor temperature The thermister circuit is c
179. ptional during operation Note the Process pressure from the pump and reference this number 0 gpm on the pump curve see Description section entitled Pump Curves If there is no significant difference between the pump curve pres sure and the actual pressure the pump impeller is operating properly If there is a difference of 5 psig or more between the actual pressure and the pump curve readout replace the pump See Troubleshooting section entitled Replacing Pump Components NOTE When using the motor pump in the pump tank the From Process water pressure is deter mined by the height above the inlet Add 1 psi for every 2 31 ft 70 4 cm above the inlet Replacement motor pumps and water pressure gauges are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 Maintenance 5 23 TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation speed 5 24 Maintenance FUNC 4 gt Reloading Factory Default Parameters Reloading the factory default parameters should only be performed when all other troubleshooting methods have been attempted Reloading default parameters will reset all parameters except Run Times PID Values Cycle Counters Controller Option Type Chiller Type Autofill Option and Hot gas Bypass valve present To reload all factory default parameters
180. r recommends that the wire terminations be tightened during any servicing of the chiller Weekly or as often as needed g Checking temperature and pressure readings Check that the temperature displays on the control screen on the condenser inlet and outlet and pressure gauges not included on the condenser piping indicate normal operation Checking efficiency Review the performance data on the Maintenance Log found in Appendix B If you notice a decrease in efficiency over time check all heat transfer surfaces of the evaporator and condenser for fouling Clean as needed Checking refrigerant site glass There should not be any bubbles in the sight glass unless when the Hot gas Bypass valve HGBP is energized See Maintenance section entitled Checking Refrigerant Charge Checking reservoir level Check the water level gauge on the back of the chiller If fluid level is low fill See Maintenance section entitled Checking Reservoir Level Cleaning the Evaporator and Condenser Y strainer See Maintenance section entitled Cleaning the Evaporator and Condenser Y Strainer Preventative Maintenance Schedule Monthly Inspecting cooling water treatment system If your chiller uses a cooling water treatment system maintain proper chemi cal levels and follow the recommendations of your water treatment specialist Otherwise change water in the reservoir tank monthly to decrease water hardness See Appendix D entitl
181. ration Control Function Descriptions Screen SCREEN 1 Read only 8 8 8 8 8 8 8 8 x V1 01 CHiL 5 2 9 22 a Air n e 1 22 A D Nn 2 9 a 5 un o gt B iq ojl 2 5 o E 5 Actual Setpoint Function Once power is turned on this screen is displayed for 2 seconds This screen is a display test to ensure that all the segments of the LED display are functioning properly Once power is turned on and Screen 1 has been displayed for 2 seconds this screen will be displayed for another 2 seconds This screen displays the current software version of the chiller After Screen and 2 have been displayed this screen will be shown for an additional 2 seconds This screen shows the designa tion of the type of chiller the control is operating Air or 20 This screen is the top screen of the Main Status Menu It displays both actual and setpoint temperatures The top screen shows the Actual temperature of the To From or Average process coolant The bottom screen shows the user entered process temperature Process temperature ranges 40 70 F 4 4 21 1 C Once this screen is displayed use the and buttons to change this setting Holding down the or buttons causes this setting to ramp up or down at a faster rate Cont
182. re high temperature liquid is metered back to the evaporator by the expansion valve TXV changing it to a low pressure low temperature liquid vapor left side as view from the control panel right side as view from the control panel Description 2 7 Portable Chiller Features Water cooled models left side as view from the control panel 2 8 Description 1 Hot gas bypass valve HGBP 2 Relief valve o Compressor 5 Receiver Q Liquid line solenoid valve LLSV TX valve Expansion valve Process pump Pump reservoir right side as view from the control panel Filter dryer Evaporator D Flow switch B Y strainer eo To temperature sensor ee gt From temperature sensor Evaporator temperature sensor Liquid line sight glass Portable Chiller Features continued Air cooled models o
183. re performing any work on this item disconnect and lock out elec trical power sources to prevent injury from unexpected energization or startup 1 Disconnect and lockout power to the chiller Interconnecting control ribbon CONAIR 2 Open electrical enclosure 3 Check the short to ground with an ohm meter Connect an ohm meter to each of the three terminal screws and to the grounding lug Test all three for resistance The minimum resistance to ground should be 1 megohm If it resist ance is less than 1 megohm there is a leak in the system Terminals leads 4 Close the electrical enclosure 5 Turn the optional disconnect switch to the position and or apply main power Checking Pump Rotation A WARNING All wiring disconnects and fuses should be installed by a A qualified electrical technician in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only power levels other than what is specified on the the machine serial tag and data plate To check for proper pump rotation 1 Press and hold the Start button for seven 7 seconds to activate Manual Pump mode and the setpoint will flash on the chiller s dual LED display Press the Sto
184. reen displays the Ramp to Rate When pressing the or buttons to change the temperature rate at which the process temperature will achieve setpoint temperature Use the or buttons to change this setting The range is 0 to 120 F 0 to 67 4 C degrees per minute This screen displays the Ramp to Setpoint Hold Back Band This setting is used to allow the temperature ramp setting Screen 21 to achieve a linear temperature profile by allowing a wider temperature delta Once this screen is displayed use the and buttons to change this setting The range is 0 to 50 F 0 to 28 1 C This screen displays the Autofill Deadband Delay when the Autofill option is includ ed Autofill automatically fills the chiller s internal reservoir A normally open circuit float switch that must be installed inside the reservoir indicates to the control that it is full See Appendix G entitled Installing Autofill optional When the float switch circuit closes it stops the flow of coolant This setting delays the shutoff signal and overfills the reservoir to eliminate float switch bobbing that can trigger an alarm condition On this screen use the or buttons to change this setting The range is 0 to 60 seconds NOTE Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Operation 4 19 NOTE Grey s
185. ressing the Acknowledge Alarm button a second time will clear the alarm If the alarm reappears the cause has not been resolved A Few Words of Caution N WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should only be installed adjusted and serviced by a qualified technician who is familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by a qualified electrical technician in accordance with electrical codes in your region WARNING Electrical Hazard Before performing any work on this item disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equipment CAUTION Hot Surfaces AN Always protect yourself from hot surfaces when working on the chiller especially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting WARNING Refrigerant Hazard Only a certified refrigerant technician should examine and correct problems involving the refrigerant circuit Troubleshooting 6 3 Symptom The control is not lit and the chiller is not w
186. rol Function Descriptions continued Screen n p 6 ri e E C mE o s un d trj 77 C e o 3 E E ay TI L3 p nw pri e TM Ev t o 3 E X2 e Ax trj trj p 9 SbY Function This screen shows the To Process tem perature measured by a RTD at the To Process outlet of the chiller This screen shows the From Process temperature measured by a RTD at the From Process inlet of the chiller This screen displays the evaporator leaving temperature This screen displays the chiller s status mode RUN STANDBY MANUAL AUTOTUNE and TEST modes See Operation section entitled Control Function Descriptions Screens 10 and 11 Operation 4 15 TIP Pressing and hold ing the Scroll button while pressing the Function button will increase menu naviga tion speed NOTE Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Operation Control Function Descriptions Screen n Q d Z No u 5 2 e trj trj trj tri 2 2 Q el c lt F c OFF o 5 Fo 7 a E XE Out 70 Function This is the first scree
187. rthSmart ECW and ECA Series and Maintenance section entitled Checking Pump Performance for water flow requirements To adjust the Bypass valve 1 Close the To Process and From Process valves factory optional 2 Turn the Bypass valve adjustment to the fully opened position a oe 55 D zi Bypass valve To Process valve Factory optional From Process valve Factory optional Actual 3 Manually start the chiller s pump See Installation section entitled Checking Pump Rotation 4 While the pump is running slowly close the bypass valve until FSL Flow Setpoint Switch Loss is displayed in the chiller s readout Once this error is displayed the chiller will shutdown 5 Open the bypass valve slightly and manually restart the pump See Installation section entitled Checking Pump Rotation 6 If the FSL alarm reappears and the pump shuts off continue slightly opening the Bypass valve and manually restarting the pump until the alarm no longer appears 7 Open the To Process and From Process valve factory optional the chiller is now ready for normal operation Installation 3 15 A IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only 3 16 Installation Installing Alarm Indicators AN WARNING A
188. ry Optional To Process valve Oo Factory Optional 4 40 Operation Starting the Chiller 1 Make sure the To Process valve is in the fully open position and the From Process valve is in the 3 4 open position BR NOTE Before pressing the Start button check to 2 Turn on the main power to the chiller Ensure that the chiller s optional ensure the Compressor LED is disconnect dial is in the ON position This powers up the control and the not flashing The chiller s display lights will illuminate compressor will not start if the LED is flashing 3 Press the START button If everything is installed correctly The pump LED will illuminate Compressor contactor Liquid Line Solenoid valve LLSV and Hot gas Bypass valve HGBP will energize Hot gas Bypass valve will remain on for three 3 seconds the Bypass LED will illuminate Bypass Pump Q NOTE The above description is a normal start up procedure when the actual process temperature is above setpoint temperature EarthSmart Chiller SX Actual Setpoint Start Button Setpoint Adjustment Stop Button Buttons Operation 4 41 i gt m 5 L4 Stopping the Chiller 1 Press the STOP button The Liquid Line Solenoid valve LLSV will de energize causing the compressor to pump down the compressor pumps refrigerant from the N low side of the compressor to the high side until the low pr
189. s Phase Protection The INT69SCY module provides phase protection for the compressor The module senses the correct phase sequence phase loss and voltage sag for each leg L1 L2 and L3 of the incoming power supplied to the compressor At installation the three phases of the power supply must be wired in the correct 120 phase sequence This will ensure the compressor will start and operate in the correct clockwise direction The INT69SCY module trips M1 M2 contacts open when the module senses a phase loss There is a 5 minute time delay before the module attempts a restart If all three phases are present then the module will reset M1 M2 contacts will close and the compressor will start and run If not the module will attempt a restart after another 5 minute time delay After 10 failed attempts to restart the module will lock out M1 M2 contacts will remain open and can only be reset by removing the power from T1 T2 for a minimum of 5 seconds The INT69SCY is intended to protect the compressor The L1 L2 L3 and S1 S2 leads are pre wired on the compressor and are engineered to work in conjunction with the motor protector module The module Compressor Module Troubleshooting continued leads should not be moved or extended because of the possibility of inducing electronic noise into the INT69SCY which could cause false trips of the and then measure the voltage across the M1 M2 contacts module Module and Sensor F
190. se the load on the chiller Contact a Conair representative for correct chiller sizing for your process Lower or increase the initial process fluid temperature to within normal operation conditions Increase the Loop Break timer duration See Operation section entitled Adjusting the Process Loop Break Timer Lb t Re tune the chiller See Operation sec tion entitled Autotuning Requirements and Autotuning Procedure Reset factory defaults See Maintenance section entitled Reloading Factory Default Parameters Check to ensure all water valves are open at the chiller and auxiliary equip ment See Maintenance section entitled Checking Pump Performance Check to ensure the chiller s water reservoir is filled Check the pump s functionality See Operation section entitled Control Function Descriptions Screen 100 Reset to proper pump full load amps or correct overload condition Incorrect power phasing See Installation section entitled Checking Pump Rotation Troubleshooting 6 13 6 14 Symptom Flow Switch Loss continued FSL Refrigeration Pressure Switch High PSH S NOTE Manual reset ting of the High Pressure switch is required to clear this alarm See Appendix M entitled Resetting the High Pressure Switch Troubleshooting Shut Down Alarms that could damage your material or chiller Possible cause Damaged or improperly installed flow switch Clogged Y S
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193. sing the Supervisor s Password NOTE Temperature off sets are only to be used in the event the RTD temperature does not match your actual tem perature Operation Control Function Descriptions continued Screen SCREEN 30 FL 3 u tri 2 a E Z S bi 2 Z bi 3 Function This screen displays the time period the chiller s control will sample the Average temperature A long time duration between samples will allow for temperature jumps a low duration will help accuracy but may trigger alarms due to temperature fluctua tions Use the and buttons to change this setting The range is 0 1 to 10 sec onds This screen displays the Process Temperature Gain Offset This setting is used to compensate for the temperature resistance of the Process RTD con nection Use the and buttons to change this setting The range is 1000 to 1000 F 555 6 to 555 6 C This screen displays the From Process Temperature Gain Offset This setting is used to compensate for the temperature resistance of the From Process RTD connection Use the and buttons to change this setting The range is 1000 to 1000 F 555 6 to 555 6 C This screen displays the Average Temperature Gain Offset This setting is used to compensate for the temperature resistance of the Average RTD c
194. splays the Process High Temperature Shutdown Setpoint This set ting is used to shut down the chiller when the To Process coolant temperature exceeds the user entered maximum coolant temperature set at this screen This is used to prevent any damage to the chiller or end product Use the and buttons to change this setting The range is 50 to 10098 10 to 37 8 C This screen displays the Process High Temperature Shutdown Inhibit Time This setting is used to adjust the amount of time after chiller start up the Process High Temperature Shutdown input will be ignored This is used so that the chiller can lower the process temperature to normal operating conditions Use the and buttons to change this setting The range is 0 to 900 seconds This screen displays the Process High Temperature Shutdown Delay Time This setting is used to adjust the amount of time after the chiller has detected a Process High Shutdown that its input will be ignored This is used to eliminate nuisance alarms during startup or operation Use the and buttons to change this setting The range is 0 to 60 seconds This screen displays the Process Low Alarm Setpoint This setting is used to activate a Process Low Alarm when the chiller s process control input Screen 27 temperature falls below the user entered minimum coolant temperature set at this screen This is used to prevent any damage to the chiller or end product Use t
195. ssure This screen displays the status of the Low Refrigerant Pressure Switch This switch is normally closed and opens when low pressure 110 PSI 7 6 bar is reached from the compressor during a Low Pressure Alarm On no low pressure Off low pressure This screen displays the status of the Fan Cycling Pressure Switch that enables the fan on top of an air cooled chiller to acti vate depending on the pressure at the out let of the condenser This switch is nor mally open and closes when pressure at the outlet of the compressor is above 450 PSI 31 0 bar On fan on Off fan off when below 320 PSI 22 1 bar ec Q TIP Pressing and hold ing the Scroll button while pressing the Function button will increase menu naviga tion speed NOTE Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password WARNING Only a qualified electrical technician trained in the use of this equipment and in avoiding exposure to voltage hazards should perform pro cedures that require access to the chiller while power is on Operation 4 37 Control Function Descriptions continued Function S NOTE Screen 102 will only be shown when the optional Autofill hardware and axillary board are installed This screen displays the status of the optional Autofill Switch float valve that enables the ch
196. st current information 2 12 Description Pump curves ECA Series Air cooled ELI I ES E 100 90 o HAIA GENE Ev Pressure psi 3 LL LL AAT SH LAL A ts IA TAT AT YI IAT IAT y 12 ANA e 10 AKTAI IST 11 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Flow Rate gpm SPECIFICATION NOTES Pump availability 0 75 Hp standard for 1 5 ton 1 Hp standard for 3 ton 1 5 Hp standard for 5 7 5 and 10 ton and optional for 1 5 ton 2 Hp standard for 15 ton and optional for 3 ton 3 Hp A optional for 3 5 7 5 and 10 ton 3 Hp B standard for 20 and 25 ton 5 Hp standard for 30 ton and optional for 5 and 15 ton 7 5 Hp optional for 7 5 10 20 25 and 30 ton 10 Hp optional for 15 ton 15 Hp optional for 20 25 and 30 ton Pump curves do not reflect pressure drops due to internal piping These pump curves are non overloading using the service factor of the motors Specifications may change without notice Check with your Conair representative for the most current information Description
197. sword Press the Function button to save the password entry and exit to the Main Menu Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual Setpoint Press the Scroll button until the Process Loop Break Timer screen Screen 69 is displayed Actual Setpoint Use the or buttons to increase or decrease the amount of time delay Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu Adjusting the Alarm Silence Timer ALS This setting is used to adjust the amount of time after the Alarm TIP Pressing and holding the Acknowledgment button has been pressed that the optional beacon and visual Scroll button while press alarm indicators will be deactivated If after the Alarm Acknowledgment ing the Function button button has been pressed and the alarm condition has not been satisfied it will will increase menu navigation re activate The range for this setting is 0 to 120 minutes and the standard default speed setting is 10 minutes To adjust the Alarm Silence Timer 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main Menu FUNC 3
198. t Operation 4 55 m 5 L4 NOTE Upon chiller start up If an alarm condition exists both the Inhibit and Delay time settings will be additive Both times will have to expire before the chiller s control will indicate an alarm condition WARNING Only a quali fied electrical technician trained in the use of this equipment should adjust this setting Improper adjustment can be harm ful to the compressor s life span and may void warranty E ec TIP Pressing and holding the 4 56 Scroll button while press ing the Function button will increase menu navigation speed Operation Setting Alarm Parameters The EarthSmart Chiller alarm parameters can be set according to your particular application Most alarms include an inhibit time and a delay time before actually indicating an alarm condition The inhibit time and delay times are used to avoid repeated alarming that may otherwise allow the chiller to resume normal operating conditions Inhibit Time This is the time the chiller s control will ignore an alarm input while initially starting the chiller Pushing the Start button Delay Time This is the time the chiller s control will ignore an alarm input during normal operating conditions of the chiller Adjusting the Low Pressure Inhibit Time LP i This setting allows the user to set the time from when a low refrigerant pressure alarm is detected
199. t communica tions will require configuration through the ethernet control software 4 34 Operation Control Function Descriptions continued Screen SCREEN 87 FiL oFF ZZ oo e lt n Z 2 o 2 bAud 9600 Function This screen displays the optional AutoFill feature On or Off Use the and buttons to toggle between or off Additional hardware must be installed for this feature to be activated See Appendix G entitled Installing Autofill optional This screen displays the Glycol Enable Disable screen Use the and buttons to toggle between yes or no See Operation section entitled Glycol Operation Enable Disable This screen displays the Communication ID This is used to label where the chiller will be on a Modbus network Use the and buttons to select the Modbus address The range is to 247 See Operation section entitled Setting Serial Modbus Communication ID This screen displays the Baud Rate The Baud Rate can be changed to 2400 4800 9600 and 19200 according to you particu lar communications setup Use the and buttons to select the Baud Rate See Operation section entitled Adjusting Baud Rate Control Function Descriptions Screen SCREEN 91 Ci OFF o wn tr ZA Ne N z oFF SCREEN 93 PPr oFF SCREEN 94
200. t discharge pres sure falls below the fan cut 4 If the process temperature begins to drift below the setpoint temperature out pressure 320 PSI the HGBP will cycle to increase actual temperature to maintain the setpoint 22 1 bar temperature Bypass LED will illuminate If actual temperature drops below the setpoint temperature by 4 F 2 2 C for more than four 4 seconds this will cause the AQ compressor to start its shut down sequence Within thirty 30 NOTE For water cooled mod els the condenser water reg ulating valve will remain open until the coolant pressure drops below the valve s set ting seconds the chiller s compressor will shut off but the pump will remain on and functioning The compressor will start only after the guaranteed off timer has expired and when the actual temperature is above the setpoint temperature by 2 F 1 1 C Operation 4 43 Adjusting Setpoint Temperature Use the temperature setpoint to set the temperature of the process coolant that will exit the chiller at the Process outlet Depending on the chiller s Process Variable Selection the actual temperature will be measured from the process to the process or an average of both See Operation section entitled Adjusting the Process Variable Selection To adjust the temperature setpoint 1 Use the or buttons to increase or decrease the temperature setpoint A from the Main Menu screen Holding
201. t flowing until the button is pressed NOTE Screen 109 will only be shown when the optional Autofill hard ware and axillary board are installed Operation 4 39 Before Starting Before you start daily operation of the chiller you need to perform scheduled preventative maintenance See Maintenance section entitled Preventative Maintenance Schedule N WARNING Electrical Hazard Before performing any work on this item disconnect and or lock out electrical power sources to prevent injury from unexpected energization or startup Daily maintenance includes Checking electrical connections Checking process fluid level in the pump tank Checking the condenser coil for debris air cooled only Y Strainer water cooled Verifying pump discharge pressure Inspect piping for leaks and to ensure all valves are open Before starting the chiller be sure to Open the Process valve factory optional to the full open position Open the From Process valve factory optional to the 3 4 open posi tion You will need to adjust this valve when the chiller is running to obtain the desired pump discharge pressure To find the approximate water flow see Description section entitled Pump Curves Open the supply valve if the chiller has the optional Autofill function NOTE All panels must be in place before starting an air cooled chiller From Process valve Facto
202. tended completely through the evaporator 8 Wire the RTD to the inlet port on the back of the electrical enclosure Removing Pump Components The pump s wet end impeller motor and seal assembly can be removed for service 1 Disconnect and lockout power to chiller 2 Open the drain fill valve and drain the water from the chiller Open side Fill Drain valve 3 Open the right side of the chiller As viewed from the control 4 Remove the bolts connecting the pump motor to the pump base 5 Remove the pump volute bolts 6 Inspect clean and replace pump parts as needed Separate the pump assembly from the pump volute casing by prying the flanges and pulling apart Follow the disassembly and reassembly procedures in the pump manufacturer s manual that accompanies this User Guide NOTE These connections may vary depending on the model you have pur chased Be sure to see the labeling on your par ticular unit N IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only Replacement pump compo nents are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 Troubleshooting 6 23 N IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specif
203. ter cooled 1 Disconnect and or lockout power to the chiller 2 Shut off the Process and From Process valves factory optional 3 Open the Fill Drain valve Close the valve when the water level gauge on the back of the chiller reads half full 4 Remove the left side panel As viewed from the control continued 5 16 Maintenance Cleaning the Evaporator and Condenser Y Strainer continued Air and Water cooled 5 Locate the evaporator Y strainer at the discharge of the Evaporator pump Evaporator Y strainer 6 Remove the center plug from the cap to drain any water in the strainer by using an appropriately sized pipe wrench 7 Remove the strainer from the strainer housing 8 Inspect the strainer Check for holes tears or filter blinding clean or replace as necessary Replacement Y strainers are 9 Re install the strainer and strainer cap Properly seal all piping with approved available from Conair Teflon tape or pipe dope Contact Conair Parts IMPORTANT Check to ensure the strainer is properly seated before applying the strainer 800 458 1960 From outside of the cap Crushing of the strainer can occur if it is not fully inserted back into the strainer United States call housing 814 437 6861 10 Check to ensure no leaking has occurred before returning the chiller to normal operation continued Maintenance 5 17 Cleaning the Evaporator and Condens
204. ter quality should be maintained at a pH level of 7 4 but not less than 6 0 for CE NOTE All brazed plate heat proper heat exchanger life exchangers are copper and stainless steel To clean the brazed plate adapter NOTE EarthSmart Chiller 1 Disconnect and lock out main power models 1 5 3 and 5 have Tube in Tube style heat exchangers made with cop per and steel Follow rec ommended guidelines of the 3 Prepare a 5 solution of Phosphoric acid or Oxalic acid and water Do not cleaning solution supplier heat the acid solution for mixtures based upon the severity of fouling 2 Remove the chiller s side panels 4 If cleaning the evaporator shut the To and From Process valves and the drain reservoir See Installation section entitled Drain Connection NOTE These connections 4b If cleaning the condenser close the condenser inlet and outlet valves and may vary depending on the drain the condenser piping Hiis 5 on your particular unit 5 If cleaning the evaporator disconnect the pump from the heat exchanger Install a cap in the opening of the heat exchanger where the pump was connected 5b If cleaning the condenser disconnect piping to the condenser Install cap in the opening of the condenser where the piping was connected continued Maintenance 5 7 S NOTE All brazed plate heat exchangers are copper and stainless steel NOTE EarthSmart Chiller models 1 5 3 and 5 have Tub
205. ter this number to make changes to screens where the supervisor s password is neces sary to use or change a function of the chiller 4 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu NOTE The Supervisor s Password will be active for ten minutes After ten minutes the password must be entered again to alter supervisor password screens Operation 4 45 ec TIP Pressing and holding the 4 46 Scroll button while press ing the Function button will increase menu navigation speed Operation Autotuning Requirements Autotuning enhances the EarthSmart Chiller control s ability to govern actual process temperature in relation to setpoint temperature It is advised to perform an Autotune only under normal operating conditions and specifications See below for requirements for a successful Autotune The chiller must be in Stop mode and under normal load All components of the chiller must be in proper working order The chiller s process coolant should be 20 F 11 2 C above or below the user entered setpoint The chiller can Autotune from above the user entered setpoint However since the chiller controls the process temperature by introduc ing hot gas into the process it is recommended to start with a process tempera ture that is 20 F 6 7 C below the user entered setpoint See Troubleshooting secti
206. th Motor Running Turn Off And Wait Until Cool May Need More Than 1 Hour To Reset www EmersonClimateContractor com ASTP Figure 2 Compressor Module Troubleshooting continued discharge gas overheating Events such as loss of charge evaporator blower failure or low side charging with inadequate pressure will cause the discharge gas to quickly rise above a critical temperature Once this critical temperature is reached the ASTP feature will cause the scrolls to separate and stop pumping but allow the motor to continue to run After the compressor runs for some time without pumping gas the motor protector will open Depending on the heat build up in the compressor it may take up to two hours for the ASTP to reset The addition of the Advanced Scroll Temperature Protection makes it possible to eliminate the discharge line thermostat previously required A graphic explanation and a short video clip are available on the web site www emersonclimatecontractor com ASTP Compressors with this feature will have the Advanced Scroll Temperature Protection label Figure 2 located directly above the terminal box Pressure Controls Both high and low pressure controls are required and the following are the minimum and maximum set points Refer to Table 4 for proper settings IPR Valve The 7 through 15 horsepower refrigeration scroll compressors DO NOT have an internal high pressure relief valve To provide safe operation a high
207. the current When an alarm condition is Press Start to start the units of measurement for tempera detected this LED will be illumi chiller Press Stop to ture nated stop the chiller Operation EarthSmart Chiller Control Functions Chiller functions are values that you can set or monitor Press the Scroll button to access a function within a Menu list until the parameter to be set or monitored appears in the Actual LED display Q NOTE Grey shaded screens denote supervisor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Control Function Flow Charts The charts beginning on page 4 6 provide a quick summary of the control functions For an explanation of each control function see Operation section entitled Control Function Descriptions How to Navigate the Menu Tree To scroll through the Main Status Menu use the button To access the Process Setup Analog Input Setup Alarm Setup Running Time Status Setup Test Mode and Alarm History menu trees push and release both the Scroll and Function buttons together Once you have selected a menu tree use the Scroll button the scroll through the screens Press the Scroll button to save any setting changed within the selected menu If no changes are made within a menu tree the control will automatically return to the Main Status Menu after two 2 minutes Scroll Button Function Butto
208. the number of compressor on off cycles per hour in which the con trol will allow before activating a shut down alarm If the number of compressor On Off cycles exceeds this setting the chiller will shutdown Use the and buttons to change this setting The range is 2 to 15 cycles hour Operation 4 29 Control Function Descriptions Screen SCREEN 73 4 30 Operation Function This screen displays the Freeze Protection Shutdown Alarm Setpoint This setting is the minimum low temperature setpoint before the chiller will immediately shut down to avoid freezing of the process fluid Use the and buttons to change this setting The range is 35 to 50 F 1 7 to 10 C or if a glycol mixture is used 15 to 50 F 9 4 to 10 C Control Function Descriptions Screen Function n x 2 E This is the first screen of the Running Time Status Menu tree To access this run screen press and release both the and Function buttons until this screen is shown on the chiller s dual LED display ec Pressing and hold tnn ing the Scroll button while pressing the Function button will increase menu naviga This screen displays the total run time tion speed hours x 100 of the compressor n Ww E 2 UA e a o 30 0 u al Ww 22 D b C Q ES This screen displays the total number of cycles cycles
209. to when the alarm signals upon chiller start up The range for this setting is 0 to 120 seconds and the standard default setting is 60 seconds To adjust the control s Low Pressure Inhibit Time 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password 2 Press the Function button to save the password entry and exit to the Main Menu 3 Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual continued Adjusting the Low Pressure Inhibit Time LP i continued 4 Press the Scroll button until the Low Pressure Inhibit screen Screen 50 is displayed A 5 Use the or buttons to increase or decrease the amount of time delay 9 6 Press the Scroll button to lock in the selection or press the Function Ke button to lock in the selection and exit to the Menu Setpoint o D 5 Ex gt Operation 4 57 A WARNING Only a qual ec 4 58 Adjusting the Low Pressure Delay ified electrical techni Time LP d cian trained in the use of this equipment This setting allows the user to set the time from when a low refrigerant pressure should adjust this set alarm is detected when the chiller is in normal operation The range for this setting ting Improper adjust is 0 to 30 seconds and the standard
210. tons to turn on or off the decimal point readout Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu 4 gt 4 50 Operation Glycol Operation Enable Disable TIP Pressing and holding the Scroll button while press The EarthSmart Chiller s process coolant can be mixed with glycol for lower ing the Function button process temperature operation Proper water to glycol mixture is required for your will increase menu navigation specific process temperature The EarthSmart Chiller does not monitor the percent speed age of glycol to water See Installation section entitled Filling the Chiller amp WARNING Warranty does NOT include evaporator freeze up NOTE M Setpoint must be adjusted lower when enabling Glycol To enable disable glycol operation operation see Operation sec tion entitled Adjusting the 1 Enter the Supervisor s password within the Setup Menu Branch See Process Low Alarm Setpoint Operation section entitled Using Supervisor s Password L AL 2 Press the Function button to save the password entry and exit to the Main Menu FUNC 3 Press and release both the Scroll and Function buttons together until the main screen of the Setup Menu Screen 83 is displayed FUNC ChE D 5 ERE gt es Setpoint 4 Press the Scroll button until the
211. tpoint 4 Press the Scroll button until the Units screen Screen 85 is displayed Actual 5 Use the or buttons to toggle between Fahrenheit or Celsius 6 Press the Scroll button to lock in the selection or press the Function button to lock in the selection and exit to the Main Menu ec TIP Pressing and holding the Scroll button while press ing the Function button will increase menu navigation speed FUNC H FUNC Operation 4 49 v L4 Enabling Disabling Display Decimal Point for Temperature ee TIP Pressing and holding the The EarthSmart Chiller s display can be programmed to display temperature units Scroll button while press Fahrenheit or Celsius up to one decimal point ing the Function button will increase menu navigation To enable disable decimal point temperature control readout speed 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password FUNC 2 Press the Function button to save the password entry and exit to the Main Menu FUNC 3 Press and release both the Scroll and Function buttons together until the main screen of the Setup Menu Screen 83 is displayed Actual Setpoint C 4 Press the Scroll button until the Display Decimal Point screen Screen 86 is displayed Setpoint Use the or but
212. trainer The evaporator is frozen Clogged or damaged pump impeller Load too high for chiller The high side of the compressor is above 550 PSI Air cooled only The high side of the compressor is above 550 PSI Water cooled only Clogged or blocked condenser coils Insufficient clearance around the chiller Ambient air temperature is higher than 95 F 35 C Condenser water is above 85 F 29 4 C The chiller has automatically shut down because it has detected a serious problem Solution See Maintenance section entitled Checking or Cleaning the Flow Switch See Maintenance section entitled Cleaning the Evaporator and Condenser Y Strainer Stop the chiller and manually start the pump Let the chiller stand in Stop mode until the evaporator thaws See Maintenance section entitled Checking Motor Performance Reduce the load on the chiller Fan motors are damaged Replace fan assembly Fan overload has been tripped reset overload Reduce condenser water temperature See Maintenance section entitled Cleaning the Evaporator and Condenser Y Strainer Clean condenser coils See Maintenance sections entitled Cleaning the Air cooled Condensers and Cleaning the Brazed Plate Evaporator or Water cooled Condenser Increase clearance around the chiller See Installation section entitled Preparing for Installation Reduce ambient air temperature or move the chiller to a lower
213. u navigation setting is to 30 seconds and the standard default setting is 5 seconds Speed To adjust the control s Flow Switch Alarm Delay Time 1 Enter the Supervisor s password within the Setup Menu Branch See Operation section entitled Using Supervisor s Password FUNC 2 Press the Function button to save the password entry and exit to the Main Menu G FUNC 3 Press and release both the Scroll and Function buttons together until the main screen of the Alarm Setup Menu Screen 49 is displayed Actual Setpoint 4 Press the Scroll button until the Flow Switch Delay screen Screen 53 is displayed Actual A Setpoint 5 Use the buttons to increase or decrease the amount of time delay button to lock in the selection and exit to the Main Menu 6 6 Press the Scroll button to lock in the selection or press the Function 4 60 Operation Adjusting the Process High Alarm Setpoint H AL This setting ensures the chiller does not exceed maximum operational temperature ee TIP Pressing and holding the and alerts the user with a passive alarm to abnormal operating temperatures The Scroll button while press range for this setting is 0 to 85 F 17 to 29 4 C and the standard default set ing the Function button ting is 85 F 29 4 C will increase menu navigation speed To adjust the control s Process High Alarm Setpoint 1 Enter the
214. unctional Check b The following field troubleshooting procedure can be used to evaluate the solid state control circuit Refer to Table 6 for a technical data summary Module Voltage Supply Troubleshooting Verify that all wire connectors are maintaining a good mechanical connection a If the measured voltage is equal to the control volts then the M1 M2 contacts are open If the measurement is less than 1 volt and the compressor is not running then the problem is external to the INT69SCY or INT69SU module If the voltage is greater than 1 volt but less than the control voltage the module is faulty and should be replaced Replace any Sensor Troubleshooting connectors that are loose Measure the voltage across T1 T2 to ensure proper supply voltage Determine the control voltage by using a voltmeter Remove the leads from S1 S2 and then by using an ohmmeter measure the resistance of the incoming leads CAUTION Use an Ohmmeter with a maximum Emerson P N Manufacturer P N Voltage Supply Frequency Maximum Voltage Maximum Current Minimum Current Relay Output Power Output Trip Out Resistance Reset Resistance Reset Time Manual Reset Phase Sensor Phase Monitoring Circuit Rating Trip Delay Lockout Reset For Lockout TABLE 6 071 0520 07 071 0520 05 071 0620 00 071 0641 00 T1 T2 Module Power M1 M2 Module Output Contacts 25OVAG 5 Amps 1 S2 Thermal Protection 45
215. ure Alarm Delay and Inhibit times See Operation sections entitled Adjusting the Process High Inhibit Time HA i and Adjusting the Process High Delay Time HA d See Maintenance section entitled Checking the Hot gas Bypass Valve Operation Replace the From Process RTD See Troubleshooting section entitled Replacing the RTD Check the RTD connection Resecure as necessary Troubleshooting 6 9 Passive Alarms During a passive alarm the chiller continues to operate but if ignored could lead to a condition that will shut down the chiller Q NOTE Passive alarms are controlled by the Process Variable Selection Screen 27 See Symptom Process Deviation High tdH NOTE This alarm automatically clears when the alarm condi tion is resolved Pressing the Alarm Acknowledgement button is not require The alarm will be present in the Alarm Log 6 10 Troubleshooting Possible cause Load too high for chiller Initial process temperature is too high User entered process fluid temperature is too high Process Deviation High Setpoint is too low The compressor is not running Hot gas Bypass valve is stuck open Improper Autotune Low airflow through the condenser Air cooled only Operation section entitled Adjusting the Process Variable Selection Solution Reduce the load on the chiller Lower initial process fluid temperature Lower user entered process temperature setpoint
216. user entered coolant temperature set at this screen This is used to alert the operator to possible temperature fluctuations that can effect end product Use the and but tons to change this setting The range is 0 to 85 F 17 8 to 29 4 C This screen displays the Process High Alarm Inhibit Time This setting is used to adjust the amount of time after chiller start up the Process High Alarm input will be ignored This is used so that the chiller can lower the temperature of the coolant below the temperature set at Screen 54 Use the and buttons to change this setting The range is 0 to 300 seconds This screen displays the Process High Alarm Delay Time This setting is used to adjust the amount of time after the chiller has detected a Process High Alarm that its input will be ignored This is used to elim inate nuisance alarms during startup or operation Use the and buttons to change this setting The range is 0 to 60 seconds Operation 4 25 NOTE Grey shaded 4 26 screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Operation Control Function Descriptions Screen SCREEN 57 H SA co SCREEN 58 H Si 300 H Sd L AL I Q tri tri 2 2 ON m Cc e N Qc a lt Cc Function This screen di
217. uttons to change this setting The range is 0 to 25 F 0 to 14 C This screen displays the Process Deviation Low Alarm Setpoint This setting is used to activate a Process Low Alarm when the chiller s process control input Screen 27 coolant temperature falls below the user entered coolant temperature by the amount set at this screen This is used to alert the operator to possible temperature fluctua tions that can effect end product Use the and buttons to change this setting The range is 0 to 25 F 0 to 14 C NOTE Grey shaded screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Operation 4 27 Grey shaded 4 28 screens denote supervi sor functions To access the supervisor screens see Operation section entitled Using the Supervisor s Password Operation Control Function Descriptions Screen CREEN 65 o Q 5 2 5 n 7 m trj Z dL L SCREEN 68 Lb e OFF Function This screen displays the Process Deviation High Alarm Inhibit Time This setting is used to adjust the amount of time after chiller start up that the Process High Alarm input will be ignored This is used so that the chiller can reduce the tempera ture of the coolant to within the tempera ture range set at Screen 63 Use the and buttons to change this setting The
218. w to Use the Lockout Device optional A CAUTION Before performing maintenance or repairs on this product you should disconnect and lockout electrical power sources to prevent injury from unexpected energization or start up A lockable device is available as an option to isolate the chiller from potentially hazardous electricity Lockout is the preferred method of isolating machines or equipment from energy sources Your Conair EarthSmart Portable Chiller can be equipped with the optional lockout device pictured below To use the lockout device 1 Stop or turn off the equipment 2 Isolate the equipment from the electric power Turn the rotary disconnect switch to the OFF position 3 Secure the device with an assigned lock or tag Insert a lock or tag in the holes to prevent movement 4 The equipment is now locked out WARNING Before removing lockout devices and returning switches to the ON position make sure that all personnel are clear of the machine tools have been removed and all safety guards re installed To restore power to the chiller turn the rotary disconnect back to the ON position 1 Remove the lock or tag 2 Turn the rotary disconnect switch to the ON or P position SECTION Description What is the EarthSmart Portable Chiller 2 2 Typical applications 2 3 2 3 How it works EarthSmart ECW Series Oo Water cooled
219. wiring diagram 6 Contact Conair Service or a certified refrigerant technician to replace the Hot gas Bypass valve if the valve is damaged or not functioning properly Hot gas Bypass valve Hot gas Bypass line N IMPORTANT Always refer to the wiring diagrams that came with your chiller to locate specific electrical components Illustrations in the User Guide are intended to be representative only IMPORTANT Attempting to serv ice the Hot gas Bypass valve will void any warranty Maintenance 5 15 Cleaning the Evaporator and Condenser Y Strainer Air and Water cooled WARNING Electrical Hazard Before performing any work on this item disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure that power to the chiller is OFF when doing any maintenance on the chiller Follow all safety rules when performing any maintenance on this equipment ZA CAUTION Hot Surfaces Always protect yourself from hot surfaces when working on the chiller espe cially when working on or around the compressor and condenser These devices can reach up to 160 F 71 C Allow these devices to cool before performing any maintenance or troubleshooting The EarthSmart Chiller s Y strainer s can accumulate dirt and clog quickly if it is ran in a poor water quality environment which will cause poor chiller performance To clean the evaporator Y strainer Air and Wa
220. www conairgroup com USER GUIDE UGH030 1012 EarthSmart Portable Chillers Water cooled models ECW 1 5 to ECW 30 Air cooled models ECA 1 5 to ECA 30 Corporate Office 724 584 5500 Instant Access 24 7 Parts and Service 800 458 1960 Parts and Service 814 437 6861 Please record your equipment s It s a good idea to record the model and serial number s of your equipment and model and serial number s and the date you received it in the User Guide Our service department uses this infor the date you received it in the mation along with the manual number to provide help for the specific equipment Spaces provided you installed Please keep this User Guide and all manuals engineering prints and parts lists together for documentation of your equipment Date Manual Number UGH030 1012 Serial Number s Model Number s DISCLAIMER The Conair Group Inc shall not be liable for errors contained in this User Guide or for incidental consequential damages in connection with the furnishing performance or use of this information Conair makes no warranty of any kind with regard to this information including but not limited to the implied warranties of merchantability and fitness for a particular purpose Copyright 2012 The Conair Group All rights reserved Table of Contents 1 1 Introduction Purpose of the user 1 2 How the guide is organized
221. x 100 of the compressor This screen displays the total number of cycles cycles x 100 of the Liquid Line LLvC Solenoid valve LLSV n coi Ww 2 a o 2 N E Operation 4 31 4 32 Operation Control Function Descriptions continued Screen SCREEN 78 Read only HgC 25 0 n 8 1 zZ E a ES RS PPr 681 0 2 Z 2 o 5 PPC 84 0 o 2 S w TI 2 111 0 Nn 2 Z N o B lt FnC 42 0 Function This screen displays the total number of cycles cycles x 100 of the Hot Gas Bypass valve HGBP This screen displays the total run time hours x 100 of the process pump This screen displays the total number of cycles cycles x 100 of the process pump This screen displays the total run time hours x 100 of the fan Air cooled only This screen displays the total number of cycles cycles x 100 of the fan Air cooled only Control Function Descriptions Screen SCREEN 83 Set SCREEN 84 PaSS 210 o 2 unit SCREEN 86 deCP OFF Function This is the first screen of the Setup Menu tree To access this screen press and release both the and Function buttons until this screen is shown on the chiller s dual LED

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